Operating a Forklift safely OSHA 1910.178, ANSI B56.12016, NFPA 30 By Ralph F Hall OHST

Only trained and evaluated operators can drive forklifts Employer certifies successful completion of training and evaluation Operating a forklift takes: Skill Mechanical knowledge Knowledge of workplace hazards

WRITTEN COMPANY SAFETY PROCEDURES 1. Company Forklift Policy Reviewed Annually. 2. Daily Operator Inspections Documented. Driving Training and Proficiency Documented. Forklift driver must be 18yrs old.

HOW MOST INJURIES OCCUR Overloading Causing the Vehicle to Turnover. Load Instability Causing Turnover. Obstructions in the Path of Travel or Lift. Using Forklift Outside of Design Limitations. Striking a Pedestrian.

Operator Training 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 (or previously received appropriate training).

Training Implementation Training shall consist of a combination of: Formal instruction (e.g., lecture, discussion, interactive computer learning, written material), Practical training (demonstrations and exercises performed by the trainee), and Evaluation of the operator’s performance in the workplace

Training Implementation Training and evaluation shall be conducted by a person with the knowledge, training and experience to train powered industrial truck operators and evaluate their competence.

Training Content Truck-related topics Vehicle capacity & stability Operating instructions, warnings and precautions Differences from automobile Controls & instrumentation Engine or motor operation Steering and maneuvering Visibility Fork and attachment operation & use Vehicle capacity & stability Vehicle inspection & maintenance Refueling/Charging/ Recharging batteries Operating limitations Other instructions, etc

Workplace-related topics Training Content Workplace-related topics Surface conditions Composition and stability of loads Load manipulation, stacking, unstacking Pedestrian traffic Narrow aisles and restricted areas Operating in hazardous (classified) locations Operating on ramps and sloped surfaces Hazardous environmental conditions Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup

Refresher Training 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: Unsafe operation Accident or near-miss Evaluation indicates need Different type of equipment introduced Workplace condition changes

Refresher Training An evaluation of each powered industrial truck operator’s performance must be conducted: After initial training, After refresher training, and At least once every three years

Certification The employer shall certify that each operator has been trained and evaluated as required by the standard. Certification shall include: Name of operator Date of training Date of evaluation Identity of person(s) performing the training or evaluation

Classes of Powered Industrial Trucks The Industrial Truck Association has placed powered industrial trucks into 7 classes. Class I - Electric motor rider trucks Class II - Electric motor narrow aisle trucks Class III - Electric motor hand trucks or hand/rider trucks Class IV - Internal combustion engine trucks (solid/cushion tires) Class V - Internal combustion engine trucks (pneumatic tires) Class VI - Electric and internal combustion engine tractors Class VII - Rough terrain forklift trucks

Class I - Electric Motor Rider Trucks

Class I - Electric Motor Rider Trucks Counterbalanced Rider Type, Stand-Up

Class II - Electric Motor Narrow Aisle Trucks

Class II - Narrow Aisle Trucks

Class III - Electric Motor Hand or Hand/Rider Trucks

Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

Class VI - Electric & Internal Combustion Engine Tractors

Rough Terrain Straight Mast

Rough Terrain Extended-Reach Forklifts

FORKLIFT TRAFFIC PATTERNS SETTING UP THE PATTERN: Aisles Must Be Well-Lighted and Obstruction Free. Aisles Must Be Clearly Marked and of Ample Width. Driving Surfaces Must in Good Repair. Pedestrians Must Be Accounted for in the Pattern. Regulatory Signs Must Be Prominent and Enforced. Guardrails, Door Warnings, Mirrors and Other. Standard Precautions Must Be Considered and Installed.

BASIC FORKLIFT PRINCIPLES FORKLIFT MANUFACTURER: Dictates Specific Operation of Vehicle. Maintains Operation and Maintenance Manuals. Specifies Maintenance Requirements. Consulted Concerning “Attachment’s”. First Choice for Safety Questions. Approves any modifications to forklift.

BASIC FORKLIFT PRINCIPLES OVERHEAD GUARD MAST CARRIAGE BACKREST LIFT CYLINDER TILT CYLINDERS FORKS LOAD CAPACITY 6000 lbs PROPANE ONLY

BASIC FORKLIFT PRINCIPLES TYPES OF TIRES CUSHION CUSHION TIRES - INDOORS OR SMOOTH SURFACES SOLID RUBBER SOLID TIRES - PUNCTURE PROOF - SMOOTH INDOOR SURFACES CONSULT YOUR VEHICLE OWNERS MANUAL

BASIC FORKLIFT PRINCIPLES AUTO STEERING VERSES FORKLIFT STEERING: TURNING PRINCIPLE PIVOT POINT WITH AN AUTOMOBILE THERE IS NO “SWING OUT”, IN OTHER WORDS, THE VEHICLE FOLLOWS THE TURNING RADIUS OF THE FRONT WHEELS. TRAVEL AUTO

BASIC FORKLIFT PRINCIPLES AUTO STEERING VERSES FORKLIFT STEERING: TRAVEL PIVOT POINT TURNING PRINCIPLE WITH A FORKLIFT, THERE IS CONSIDERABLE “SWING OUT”, IN OTHER WORDS, THE VEHICLE FOLLOWS THE TURNING RADIUS OF THE REAR WHEELS. SWING RADIUS FORKLIFT DANGER ZONE

BASIC FORKLIFT PRINCIPLES THE RATED CAPACITY The Maximum Amount of Weight That Can Be Safely Lifted. How the Load Rests on the Forks Is Critical. The Closer the Load Is to the Backrest the Better. Can Be Found on the Nomenclature Plate of the Vehicle.

BASIC FORKLIFT PRINCIPLES PIVOT POINT COUNTER WEIGHT PIVOT POINT COUNTER WEIGHT CONSULT YOUR VEHICLE OWNERS MANUAL

BASIC FORKLIFT PRINCIPLES LIFTING PRINCIPLE MOVING THE LOAD AWAY FROM THE BACKREST CAN LOWER THE RATED CAPACITY OF THE FORKLIFT BY HUNDREDS OF POUNDS! 6500lbs REAL HEAVY PARTS INCORRECT CONSULT YOUR VEHICLE OWNERS MANUAL

BASIC FORKLIFT PRINCIPLES 6500lbs REAL HEAVY PARTS 6500lbs REAL HEAVY PARTS INCORRECT CORRECT CONSULT YOUR VEHICLE OWNERS MANUAL

BASIC FORKLIFT PRINCIPLES CENTRIFUGAL FORCES 6500lbs REAL HEAVY PARTS MOVING OR TURNING THE VEHICLE WHEN THE LOAD IS EXTENDED CAN RESULT IN TURNOVER BECAUSE OF CENTRIFUGAL FORCES APPLIED AT THE TOP OF THE LOAD!

BASIC FORKLIFT PRINCIPLES FORK ADJUSTMENT FORKS SHOULD BE SPREAD AS WIDE AS POSSIBLE TO ALLOW FOR MAXIMUM STABILITY OF THE LOAD!

PRE-USE INSPECTION Mast Roller Tracks and Chains Forks and Adjustment Fluid Levels Hydraulic Lines Lift and Tilt Cylinders Overhead Guard Mounting Fire Extinguisher Cylinder Mounting Hardware Tires Lights and Warning Devices Handbrake Steering and Brakes Driving Controls Lift Controls Seat Adjustment and Belts

TYPES OF POWER SOURCES BATTERY POWERED PROPANE POWERED DIESEL POWERED GASOLINE POWERED CONSULT YOUR VEHICLE OWNERS MANUAL

INSPECTION OF POWER SOURCES BATTERY POWERED - REQUIRES CONSTANT CHARGING - NO IGNITION SOURCES IN CHARGING AREA - FOLLOW LOCAL CHARGING PROCEDURES Wear Face shield and chemical resistant gloves.

BATTERY SAFETY PRECAUTIONS 1. Mechanical Lifting Aids Required for Battery Handling. 2. Charging Area Must Have Working Eyewash Station. 3. Wear Complete Splash Protection When Servicing Batteries. 4. Battery Charging Is Only Allowed in Predesignated Areas. 5. Ventilation Must Be Adequate to Disperse Hydrogen. 6. Ventilation Must Be Adequate to Disperse Corrosive Gases. 7. Open Flames May Not Be Used to Check Electrolyte Levels.

BATTERY FILLING PRECAUTIONS DISTILLED WATER OK!

INSPECTION OF POWER SOURCES PROPANE POWER - INSPECT TANK FOR SERVICEABILITY - INSPECT PROPANE TRANSFER SYSTEM - INSPECT TANK RESTRAINT SYSTEM - FOLLOW LOCAL REPLACEMENT PROCEDURES CONSULT YOUR VEHICLE OWNERS MANUAL

PROPANE SAFETY PRECAUTIONS 1. Extinguish Smoking Materials. 2. Ensure No Ignition Sources Are Present. 3. Wear Protective Gloves and Eye Protection. 4. Ensure Valve Is Closed Anytime the Tank Is Disconnected. 5. Follow Manufacturers Instructions for Refueling the Vehicle. 6. After Tank Is Removed From the Vehicle, Inspect for Damage. 7. If Tank Is Serviceable, Have It Moved to Empty Tank Storage. 8. If You Have Any Safety Concerns Contact Safety.

PROPANE CONNECTION CONSIDERATIONS 1. Inspection Tank for Defects and Dents. 2. Never Throw, Drag, Drop, or Roll LPG Containers. 3. Check Fuel Lines for Serviceability. 4. Check for Damage to Liquid Level Gauge. 5. Inspect Quick-Disconnect Couplings for Serviceability. 6. Inspect Threads, Valves and Fittings for Serviceability. 7. Check to Ensure Relief Valve Is Pointed in Specified Direction. 8. If You Have Any Safety Concerns Contact Safety. CONSULT YOUR VEHICLE OWNERS MANUAL

A NOTE ABOUT THE LPG TANK ACCESS VALVE Never Jam the Valve in the Open Position (When Opening the Valve). Open Fully, Then Turn Toward The Closed Position 1/4 to 1/2 Turn. This Action Prevents Jamming and Enables Quick Shut off in an Emergency. Close the Valve When the Truck Will Be Parked for Extended Periods of Time. Compressed Natural Gas SAFETY PRECAUTIONS You must be observed refilling your CNG tank 3 times to be certified. The type 2 CNG tank is rated at 3600lb.

INSPECTION OF POWER SOURCES DIESEL AND GASOLINE POWERED - INSPECT FOR LEAKS - ENSURE ADEQUATE VENTILATION EXISTS - FOLLOW LOCAL REFUELING PROCEDURES CONSULT YOUR VEHICLE OWNERS MANUAL

DIESEL AND GASOLINE SAFETY PRECAUTIONS 1. Extinguish Smoking Materials. 2. Ensure No Ignition Sources Are Present. 3. Wear Protective Gloves and Eye Protection. 4. Ensure Area Is Approved for Refueling. 5. Follow Manufacturers Instructions for Refueling the Vehicle. 6. Ensure Area Has Ample Ventilation. 7. Ensure Tank Is Not Over Filled Causing Spillage. 8. Do Not Start Vehicle Until All Spilled Fuel Is Eliminated. 9. If You Have Any Safety Concerns Contact Safety.

DEFINITION - ATTENDED VEHICLE IF OPERATOR IS DISMOUNTED: Operator Is Within 25 Feet of the Vehicle. Operator Has Line-of-Site of the Vehicle. Operator Has No Obstruction of Access to Vehicle. Load Engaging Means Is Fully Lowered. Controls Neutralized and Handbrakes Set.

Operator Is More Than 25 Feet From the Vehicle. DEFINITION - UNATTENDED VEHICLE IF OPERATOR IS DISMOUNTED: Operator Is More Than 25 Feet From the Vehicle. Operator Has No Line of Site of the Vehicle. Operator Is Obstructed From Access to Vehicle. Load Engaging Means Is Not Fully Lowered. Handbrakes Not Set.

VISIBILITY DURING FORKLIFT OPERATIONS Approach the Load Slowly and Do Not “Bump”. Know Where All Bystanders Are Located. ACME FORKLIFTS 6500lbs REAL HEAVY PARTS TRAVEL

VISIBILITY DURING FORKLIFT OPERATIONS Never Allow Bystanders Between You And a Fixed Object. Know Where All Spotters Are Located. If You Lose Sight of a Spotter, Stop and Relocate Them. ASSUME LOST SPOTTERS ARE IN YOUR PATH. ACME FORKLIFTS

TO PICK UP A LOAD Approach the Load Slowly and Straight on (Load Centered). Stop When the Tip of the Forks Are About a Foot Away. Level Forks and Adjust Fork Height. Move Forward Slowly Until Load Is Fully Against Backrest. Lift the Load High Enough to Clear Floor Obstructions. Back the Load Out Slightly From the Storage Location. Carefully Tilt Mask Back to Stabilize the Load. Ensure Rear Is Clear, Back Out.

Stop When the Tip of the Forks Are About a Foot Away. TO PUT DOWN A LOAD Approach the Delivery Location Straight On. Stop When the Tip of the Forks Are About a Foot Away. Lower Load, Carefully Level Forks. Move Forward Slowly Until Load Is in Desired Location. Lower the Load to Floor or Storage Location. Ensure Forks Are Clear of Pallet. Ensure Rear Is Clear, Back Out.

Stop About a Foot Away and Raise Forks to Desired Height. UNSTACKING LOADS Approach the Load Slowly and Straight on (Load Centered). Stop About a Foot Away and Raise Forks to Desired Height. Level Forks and Drive Forward. Move Forward Slowly Until Load Is Fully Against Backrest. Lift the Load High Enough to Clear Obstructions. Ensure Rear Is Clear, Back Out. Once the Stack Is Cleared - Lower to Desired Height. Carefully Tilt Mask Back to Stabilize the Load.

STACKING LOADS Approach the Location Slowly and Straight On. Stop About a Foot Away and Raise Load to Desired Height. Drive Forward Until Load Is Square Over Stack. Level Forks and Lower Load Until Load Is Supported. Ensure Forks Are Clear of Pallet. Ensure Rear Is Clear, Back Out.

DRIVING WITH A LOAD Travel With the Load Tilted Slightly Back for Stability. If You Can’t See Over the Load Drive in Reverse. Drive With Load Approximately Six Inches Above Surface. Never Pass Pedestrians - Pedestrians Always have right a Way! Remember That the Driving Wheels Are Your Pivot Point. Obey Traffic Rules and Local Policies. Always Slowdown to Attempt a Turn.

UNSTABLE FLOOR SURFACES Traction Problems, Skidding and Sliding Can Occur. Drive Cautiously and at Slow Speeds. Be Aware of Debris and Spills. Consider Areas Where Contractors May Be Working. Avoid Making Tight Turns. Ensure Brakes Are Applied Carefully.

OVERHEAD CLEARANCES Plan Your Route in Advance. Drive Cautiously and at Slow Speeds. Know the Mast Height and Facility Overhead Clearances. Be Careful Around Electrical Lines.

PEDESTRIAN CONSIDERATIONS HIGH TRAFFIC AREAS PEDESTRIAN CONSIDERATIONS Never Allow a Pedestrian Between You and a Fixed Object. Never Pass a Pedestrian, Pedestrians always have Right of Way. Maintain a Safe Distance When Loading and Unloading. Be Careful When Making Tight Turns. Never Assume Pedestrians Know You’re Position. Pedestrians always have the right of way.

Obey All Local Traffic Rules and Signs. HIGH TRAFFIC AREAS MULTIPLE FORKLIFT CONSIDERATIONS Obey All Local Traffic Rules and Signs. Know Where All Mirrors Are Positioned. Use Horns When Approaching Corners, Doorways, Aisles. Never Exceed the Safe Working Speed of Five Mph. Keep a Safe Distance From Other Forklifts (3 Lengths). Pass Only in Authorized Areas.

UNEVEN DRIVING SURFACES Understand the Type Tires Installed on the Vehicle. Understand the Limitations of The Tires. Approach Railroad Tracks at a 45-Degree Angle. Take Alternate Routes Rather Than Unnecessary Risks. Determine if Different Types of Vehicles Are Available.

LOADING DOCK OPERATIONS Ensure Bridge or Dock Plates Are Secure. Ensure Bridge or Dock Plates Are Rated for the Vehicle. Ensure Trailer, Truck, or Railcar Wheels Are Secured. Never Accelerate on Bridge or Dock Plates. Always Drive Straight on to Bridge or Dock Plates. Always Maintain a Safe Distance From Edges. Never Compete With Pedestrians. Trailer wheels must be chalked before entering.

TRAILER OPERATIONS Ensure the Trailer Floor Is Rated for the Vehicle Weight. Verify That the Trailer Floor Is in Serviceable Condition. Ensure the Forklift Will Not Unbalance the Trailer. Use Additional Trailer Supports If Unbalancing Is a Risk. Consider the Interior Trailer Height. Ensure the Trailer Cannot Roll Away From the Dock. Consider Lighting and Inclement Weather.

LOADED FORKLIFT RAMP OPERATIONS ALWAYS APPROACH RAMP LOAD FIRST! 6500lbs REAL HEAVY PARTS ACME FORKLIFTS

LOADED FORKLIFT RAMP OPERATIONS ALWAYS LEAVE RAMP LOAD LAST! 6500lbs REAL HEAVY PARTS ACME FORKLIFTS

UNLOADED FORKLIFT RAMP OPERATIONS ALWAYS APPROACH A RAMP FORKS LAST! ACME FORKLIFTS

UNLOADED FORKLIFT RAMP OPERATIONS ALWAYS LEAVE A RAMP FORKS FIRST! ACME FORKLIFTS

LONGITUDINAL TURNOVER TURNOVERS LONGITUDINAL TURNOVER ACME FORKLIFTS

TURNOVERS LATERAL TURNOVER ACME FORKLIFTS

LONGITUDINAL TURNOVER Usually Best to Leave the Vehicle. No Guarantee of Safety During a Longitudinal Turnover. ACME FORKLIFTS

LATERAL TURNOVER Usually Best to Stay With the Vehicle. Hold on to the Steering Wheel and Push Into the Seat. No Guarantee of Safety During a Lateral Turnover. ACME FORKLIFTS

If You’re Not Trained, You’re Not Authorized. GENERAL PRECAUTIONS If You’re Not Trained, You’re Not Authorized. Use Only on Flat, Stable Floor Surfaces. Never Move Vehicle While Elevated. Ensure Sufficient Headroom Exists Before Lifting. Look for Electrical Obstructions (Lights Etc). Engage Parking Brake During the Lift. Put Vehicle in Park During Lift. Use Spotters Effectively to Enhance Safety. Use Appropriate Fall Protection for the Person Being Lifted.

Look Before You Descend. Use Within Design Limitations. FORKLIFT ATTACHMENT Look Before You Descend. Use Within Design Limitations. Follow Local Lifting Guidelines. Follow Manufacturers Guidelines. Ensure Platform Is Secured to Forks. Ensure Both Employee’s Are Trained. Use a Fall Harness, Not “Safety Belts”. Never Exceed Your “Safe Reach” Distance. Ensure Fall Prevention Guards Are In Place. Never Move Vehicle While Platform Is Elevated. Set parking brake. Driver stay at controls. ACME FORKLIFTS

Using a Forklift is a privilege