Powered Industrial Trucks Class IV Operator Training

1910.178 OSHA General Industry Standards1910.178 OSHA General Industry Standards(Yard/Warehouse Forklifts).(Yard/Warehouse Forklifts).1926.602 OSHA Construction Standards1926.602 OSHA Construction Standards(Separate Training and Certification)(Off (Separate Training and Certification)(Off Road Jobsite Forklifts).Road Jobsite Forklifts).ANSI B56.1 - 2009ANSI B56.1 - 2009

3 Short Video Clips

1. PIT FLIPPING

2. STAY WITH THE TRUCK

3. CLEARANCE

Effective Powered Industrial Truck Operator Training Program

• Four major areas of concern must be addressed:– The general hazards that apply to the operation

of all or most powered industrial trucks;– The hazards associated with the operation of

particular types of trucks;– The general hazards of workplaces; and,– The hazards of the particular workplace where

the vehicle operates.

Powered Industrial Truck Accident Stats

Type of incident % victims killed by this type of incident

Forklift overturns 22

Worker struck by forklift 20

Victim crushed by forklift 16

Fall from forklift 9

*IMPORTANT – ALWAYS WEAR YOUR SEATBELT WHILE OPERATING A FORKLIFT.

BUREAU OF LABOR STATISTICS

Operator Training

• Safe operations– The employer shall ensure that each powered industrial

truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.

– Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the required training.

Training Program Content

– Operating instructions, warnings and precautions

– Differences from automobile

– Controls and instrumentation

– Engine or motor operation– Steering and maneuvering– Visibility

Truck-related topics

– Vehicle capacity and stability

– Vehicle inspection and maintenance that the operator will be required to perform

– Operating limitations

Training Program Content (continued)

• Operators shall receive initial training in the following topics:

– Truck-related topics– Workplace-related topics– The requirements of the OSHA Standard

(www.osha.gov.).

Training Program Content (continued)

– Surface conditions– Composition and

stability of loads– Load manipulation,

stacking, un-stacking– Pedestrian traffic– Narrow aisles and

restricted areas– Operating in hazardous

locations

– Operating on ramps and sloped surfaces

– Potentially hazardous environmental conditions

– Pinch-points

Workplace-related topics

Refresher Training and Evaluation

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

• Refresher training required when: - Certification card expires (3 years)

– Unsafe operation – Accident or near-miss– Evaluation indicates need– Different type of equipment introduced – Condition of workplace changes

Operator Training Video

Components of a Forklift Truck*

FORKLIFT STABILITY – A COUNTER BALANCE SYSTEM

• 1. A forklift operates on the simple principle of a fulcrum or teeter totter.

• 2. The fulcrum, or pivot point is the front (drive) axle. Example: If a 10,000lbs. rated forklift has a 10,000 lbs. load added to the forks, then the center of gravity shifts to the front drive axle of the forklift.

A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Theoretical)

Stability Triangle - Figure 1

Notes:1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C.

Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C.

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

Never travel with a raised load….

Operating On Ramps Or Inclines

Remember: Never turn on ramps or inclines, straight up and straight down.

When descending a grade, stopping distancewill be greater than on-level operation. Methods shall beprovided to allow for this condition. Some methods are:reduce speed, limit loads, allow adequate clear space atthe bottom of the grade, etc.

Operating On Ramps Or Inclines

Side Stability

• Side stability is the truck’s ability to resist tipping sideways under various loaded and unloaded conditions.

• There are many contributors to side stability:1. The height the load is lifted.2. The levelness of the surface.3. The amount of backward tilt of the mast.4. The wheel base of the truck.5. Speed.6. The position of the load on the forks.

Load CG

Vertical StabilityLine(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical StabilityLine(Line of Action)

Truck CG

The vehicle is stable This vehicle is unstable and will continue to tip over

Side Stability Triangle - Figure 2

The vehicle is stable

Data Plate Information

Data Plate Location

Operators Know Your Truck • Truck Model Number

• Truck Serial Number

• Attachment Information

• Maximum Lifting Capacity

• Maximum Lifting Height

• Trucks Physical Weight

• Trucks Load Center Rating

NEVER operate a truck with a damaged or missing data plate

Load Center

The majority of lift trucks have a 24 inch load center. That also means that the longest fork that can be used on that truck is 48 inches. Remember to keep the forks spaced as wide for even weight distribution.

A 24 Inch Load Center

How Do Attachments Affect My Lifting Capacity????

Any Time An Attachment Is Added To A Lift Truck, The Machines Capacity Will Change.

• The Physical Weight Of The Attachment

• May Change The Machines Load Center

Lift Cages• Lift cages must be secured to the forklift’s carriage or

forks to prevent the cage from being able to slide forward off of the forks.

• Must be completely enclosed. If chains are used, they must meet the requirements for guardrails.

• Fall protection equipment must be worn when using a forklift lift cage. The employee’s fall protection equipment must be anchored to the base of the lift cage.

• When using a lift cage, the employee must never step up on the rails. Feet must stay on the base of the platform.

Understand Pinch-Points

• A pinch-point is the area between a movable or moving object and another movable, moving, or fixed object.

• Pinch-points can cause severe injury and death to employees (examples)

• Know the pinch-points at your location. (Give examples specific to your location)

Do Not Enter or allow others to enter Pinch-Points

Eliminate the Pinch-Point

Keep drivers (vendors) out of pinch-points. They can set dunnage from the truck bed……eliminating the pinch-point.

NEVER get under a raised load and DO NOT put arms/hands in pinch-points.

Do Not Enter Pinch-Point

Do Not Enter Pinch-Point

Do Not Enter Pinch-Point

Do Not Enter Pinch-Point

Do Not Enter Pinch-Point

This is the same issue as when loading a truck. The operator could have eliminated the pinch-point.

Operating a Lift Truck

• To change directions or stop, the driver should always use the foot brake to reduce speed gradually. Never use reverse gear as a brake.

• How does a forklift operate differently than a car?

• A turn should be made from the inside corner of the aisle rather than the middle of the aisle. (remember the swing of the forks and back end!!)

Travel Speeds

INTERNAL COMBUSTION LIFT TRUCK: Top Speed - 9 MPH

ELECTRIC LIFT TRUCKS: Top Speed - 6 MPHWALKIE PALLET TRUCKS: Top Speed - 3 MPHFEET PER SECOND:

IC 13’ per secondElectric 10’ per

secondWalkie 5’ per second

Stopping Distances

BRAKE REACTION TIME:

YOUNG – Under 1 Second

OLDER – Over 1 Second (13 Feet)

BRAKE APPLIED STOPPING DISTANCE:

I.C. 15-17 Feet Electric 8-12 Feet

TOTAL STOPPING DISTANCE:

I.C. 30 Feet ELECTRIC 20 Feet

Operating a Lift Truck (continued)Lift Truck Inspections

• Must be performed prior to each shift.

• The problems must be reported immediately to your supervisor.

• Never operate a forklift if you determine it is unsafe.

LEARNING EXAM (completed as group)

Operating a Lift Truck With a Load

• Traveling Tips:– Avoid all wet/slippery spots while traveling.– Remove all obstructions such as misplaced

dunnage from your work area.– Raise the forks only high enough to clear

obstructions.– If the size of the load obstructs your view,

travel in reverse.– Know the blind spots at your location.

Operating a Lift Truck With a Load (continued)

• Traveling Tips continued:• Always travel in reverse down ramps or inclines

when loaded.• Never travel loaded or unloaded with the forks

raised more than 6-8 inches.• Do not raise or lower your forks while traveling.• Note: the lifting speed is controlled by the speed of

the engine and the amount you pull the lift lever Lowering is not controlled by the speed of the engine. Explain: Linde

• The upright should be tilted back before raising the hoist-preventing the load from sliding forward.

Operating a Lift Truck With a Load (continued)

• If you must pick up only a partial tier of wallboard, do not try to jam the forks between two sheets of board. Use a wedge to separate the board (stay out of the pinch-point).

Drywall WedgeInsert the wedge manually at the proper location. Make sure it is straight. Do not create a pinch point with the forklift during this process. Be sure to park it with the

forks lowered to the ground and set the brake.

Drywall WedgePush the wedge slowly into the lift of drywall using

the tip of the fork.

Drywall WedgeSlowly drive into the drywall with the forks on each

side of the wedge.

COVERS ON OVERHEAD GUARDS

THE OPERATOR MUST BE ABLE TO CLEARLY SEE THE LOAD UP THROUGH THE OVERHEAD GUARD.

PLYWOOD, CARDBOARD, OR ANY OTHER MATERIAL THAT THE OPERATOR CANNOT SEE THROUGH CLEARLY IS NOT PERMITTED AS A COVER.

Modifications

• When modifications involve rebuild and repair of the basic unit, they shall be made in accordance with the manufacturer’s established criteria and procedures.

Workplace Specific Hazards:

• Trainer: Review hazards that may be present at the specific location such as low lights, sprinkler pipes, blind spots, docks, electrical panel boxes, ramps/slopes, power lines, confined area, etc.

Warehouse Hazards

• Sprinkler systems/lights• Lighting• Stored/stacked material• Blind spots• Overhead doors• Pedestrians/customer traffic• Must walk yard & warehouse at location you are

going to be working.(hazards are different at each location)

Yard Hazards

• Potholes in parking lot

• Uneven pavement

• Company Vehicle traffic

• Other forklift traffic

• Customer traffic

• Pedestrians (employees & customers)

• Weather/Environment

Hazard Identification

Hazard Identification

Hazard Identification

Hazard Identification

Operators Must Read All WARNING Labels

Each Warning Label On Your Truck Is Important. Read and obey all of them to protect yourself and your co-workers

Decals

55

What is wrong here?

Under OSHA 1910.178 (a) (6) The user shall see that all nameplates and markings are in place and are maintained in legible condition

Decal Definitions

56

NOTE – Maintenance Item

IMPORTANT – You may damage the lift truck or components

CAUTION – You might be injured

WARNING – There is a hazard, could result in injury or death

DANGER – There is an “extreme” hazard that exists which will result in death or injury

WATCH for Pedestrians!

Always look over both shoulders before traveling in reverse direction.

Use horn and make eye contact to make sure you have seen each other.

Cell Phone Use

• CELL PHONES ARE NOT PERMITTED WHILE OPERATING FORKLIFTS OR ANY OTHER EQUIPMENT.

HAZARDS Of Dock Operations!

• Must use trailer restraint systems and wheel chocks.

• If tractors are not attached, make sure that the landing gear is secure

• Travel slowly on dock boards and bridge plates

• Avoid getting wheels too close to edge of the dock

• Use lights to improve visibility

Trailer Restraint

OSHA stipulates, “Brakes shall be set and wheel blocks shall be in place to prevent movement of trucks, trailers, or rail cars while loading or unloading.”

Dock Accident

60

Arms & Legs

Always keep your arms and legs inside the confines of the lift truck during operation!!

Dangers of Carbon Monoxide (CO)

• CO is odorless, tasteless, colorless, non-irritating and can’t be detected by any of the senses. Because it cannot be detected, employees can be exposed to very high levels without realizing there is a problem.

• Carbon monoxide is produced from internal combustion engines including those that use gasoline and diesel. It can also be produced by forklifts that use LPG gas.

• CO can build up in confined areas of warehouses that are not properly ventilated.

Symptoms of Carbon Monoxide Poisoning

• Headache• Dizziness• Nausea• Vomiting• Chest Pain• Confusion

Safe Handling Of Fuels

• Gasoline• Diesel Fuel• LPG • Electric (Storage Battery)

What Powers These Lift Trucks????

Read And Follow All Warnings And Safety Guidelines When Handling Any IC Fuels Or Industrial Batteries.

Diesel Fuel Safety

• If fuel gets on your skin, wash immediately with soap and water.

• If clothing gets fuel on it, remove all saturated clothing and wash with soap and water.

• If it gets in your eyes, flush eyes with low pressure water for at least 15 minutes, get medical assistance.

• If fuel gets ingested DO NOT Induce vomiting, get medical assistance immediately.

Fuel Tank Filling

• Don’t be distracted from filling by using your cell phone. In addition they are a potential ignition source when filling gasoline.

• Don’t leave your engine running while filling.

• Don’t smoke within 25’ of a fuel pump.

• Always treat all fuels with respect. Handle with great care.

LPG Fuel Tanks• LPG storage tanks are either steel or aluminum

construction

• Different size tanks 20, 33.5, or 43.5 lb.

• Tanks have an odor added to them to detect leak.

• Always store the LPG tanks in a designated cage.

Aluminum Tank Steel Tank

NOTE: Remember to always use proper lifting techniques

Storage Tank External Parts

Quick Fill Port Fuel Gauge

Liquid Discharge Port

Pressure Relief Valve

80% Fill Valve

Vapor Discharge Port

Storage Tank Internal Parts

Fuel Level Float

Liquid Withdrawal Tube

Vapor Withdrawal Tube

80% Fill Tube

Proper LPG Tank Alignment

Properly Installed LPG Tank

Alignment Holes

Battery Hazards

The main hazards of lead-acid batteries are of four types:

1. Electrolyte

2. Gasses

3. Electricity

4. Battery Weight

Batteries Create, HYDROGEN GAS

Extremely Explosive!!!

Battery Cell Exploded

Electricity

Batteries are capable of producing a very high rate of discharge in a very short amount of time. The Most likely instance, direct short, can cause serious personal injury and severe battery damage.

Battery Weight

Electric truck batteries are very heavy. They can weigh in the thousands of pounds. Use care when handling, charging, and using batteries in the truck. Proper and adequate handling equipment helps avoid working around industrial batteries.

Battery Chargers

High Amp Industrial Charger

Low Amp Single Shift Charger

Battery Charging Area With Ride On Battery Changer.

Weekend/Equalize Charge

Charger Control

Equalize charge once per month on Friday evening

Daily charge as needed

Battery Charger Don'ts

• Do not plug the charger into the truck’s plug.

• Avoid “Opportunity Charging” of the battery.

• If the charge cycle needs to be interrupted, use the manual stop button. Don’t just unplug the battery!

• Keep the cables and plug in good condition.

• Do not place any containers with fluids on top of the charger.

Sulfuric Acid

Sulfuric acid is a strong oxidizing agent that demands extreme care in handling. Small amounts can cause severe burns on skin. All contact should be avoided. Even though the acid is mixed with water to make electrolyte, small amounts of the mixture will destroy fabric and burn your skin.

Sulfuric Acid First Aid Measures

• Eye Contact– An eye wash/emergency shower should be

provided whenever battery acid exposure is possible.

– Flush eyes with large amounts of water for at least 15 minutes. Seek immediate medical attention if eyes have been exposed directly to acid.

• Skin Contact– Flush affected area with large amounts of water

using deluge emergency shower, if available, shower for at least 15 minutes.

– Remove contaminated clothing. If symptoms persist, seek medical attention.

Sulfuric Acid First Aid Measures

• Ingestion– If swallowed, give large amounts of water. Do

NOT induce vomiting or aspiration into the lungs may occur and can cause permanent injury or death.

Sulfuric Acid First Aid Measures

• Inhalation– If inhaled, remove person to fresh air and

obtain medical treatment.

Sulfuric Acid First Aid Measures

Oil Injected Into Hand

CAUTION-Do not use your HAND to check for leaks!

Parking the Forklift• 1. Fully lower the forks.

• 2. Neutralize the controls.

• 3. Set the brake.

• 4. Turn off the motor.

• 5. Block/Chock the wheels when parked on an incline or per the locations safety rules.

• 6. Park only in authorized areas.

• 7. Never park in front of an emergency exit.

• 8. Always use three points of contact when getting on or off of a forklift.

• 9. If parked and the forklift is more than 25 feet away or if you can’t see the forklift, it must be turned off.

Conclusion/Recap

• Only qualified and certified operators shall operate lift trucks.

• Inspections must be performed before each shift and equipment must be fixed prior to operation.

• All deficiencies must be reported to the supervisor immediately.

Conclusion/Recap • Avoid sudden starts or stops.• Keep feet, legs, and arms inside the forklift at all

times.• Never use a cell phone while operating the forklift or

any equipment. • Never reach through the uprights.• Drive slowly over rough surfaces.• It is the operator’s responsibility to properly inspect

the forklift and report maintenance needed.• Always watch for pedestrians.

Conclusion/Recap

• Know the capacity of your lift truck.• Slow down on wet or slippery surfaces.• No one is permitted to ride on lift trucks.• Know your locations blind spots and other

hazards.• Do not turn on inclines. • Report all accident regardless of how minor. • Do not enter pinch-points. Do not allow others to

enter pinch-points.• Always wear your seatbelt. This is our policy.

Final EXAMRead Each Question in Detail

Hands On Training

- Documented inspection of the forklift

- Component ID Test

- Location Hazard Identification

- Evaluation (loading or unloading a truck or similar tasks observed and documented by the instructor).