1. Forklift Training

2. Forklift Fatalities by Age Group 1992 -1996
There are about 100 fatalities and over 36,000 injuries each year from PIT's. From 1992 to 1996, the fatalities increased from 86 to 114, which again is why OSHA revised the standard.
As you can see from this chart, the largest number of fatalities are occurring in the age group 35 years and older. They’ve probably been using this equipment for years. What’shappening? (They may have stopped paying attention, or they stopped being careful because they’d never had a problem before.)
OSHA estimates that the new rule will prevent 11 deaths and 9,500 injuries per year.
There are about 100 fatalities each year related to forklifts
Source: Bureau of Labor Statistics

3. Content What is a Powered Industrial Truck?
Basic Engineering Principles
Safe Operating Procedures
Training, Evaluation and Certification
Special Session: Lawn mowers
There are 2 OSHA standards that apply to PIT's. They are and Regulations were established in 1971, however, the standards did not specify what kind of operator training was required. As the number of PIT's in use in the U.S. increased, so did the number of injuries and fatalities. Therefore, the New Rule was written in 1998, which mandated that all PIT operators be formally trained and certified to use the equipment.
At Virginia Tech alone we’ve identified 40 worksites where powered industrial trucks are used! They perform a variety of material handling tasks and can make moving heavy or bulky materials easier. But if not operated safely, powered industrial trucks can be dangerous!

4. What is a Powered Industrial Truck?
A mobile, power-propelled truck used to carry, push, pull, lift, or stack materials.
Does not cover vehicles used for earth moving and over-the-road hauling.
They are commonly known as forklifts, pallet trucks, rider trucks, fork trucks, or lift trucks and can be powered with either electric or combustion engines.
What do we mean by “combustion engines” ? Engines powered by gasoline, diesel, or propane.
It also does not cover agricultural equipment, though Virginia Tech has elected to roll the equipment used on our farms into this program as well.

5. Classes of Commonly-Used Powered Industrial Trucks* What Type Do We Use
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
* Note that this classification refers to commonly used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

6. Three types of the most Common Lift Trucks
Class I- Electric Motor Rider Trucks
Class III- Electric Motor Hand or Hand/Rider Trucks
Class IV- Internal Combustion Engine Trucks

7. Class I - Electric Motor Rider Trucks
Counterbalanced rider type, stand up
Three wheel electric trucks, sit-down
Counterbalanced rider type, cushion tires, sit-down (high and low platform)
Counterbalanced rider, pneumatic tire, sit-down (high and low platform)

8. Class III - Electric Motor Hand or Hand/Rider Trucks
Low lift platform
Low lift walkie pallet
Reach type outrigger
High lift straddle
High lift counterbalanced
Low lift walkie/rider pallet

9. Class IV – Internal Combustion Engine Trucks
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires
Fork, counterbalanced (cushion/solid tires)
Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

10. Basic Engineering Principles
Center of Gravity
Stability Triangle
Longitudinal Stability
Lateral Stability
Dynamic Stability
Basic engineering principles are the most misunderstood aspects for forklift operation. It is extremely important that they are understood in order to operate the forklift safely.

11. Fulcrum Principle
Forklifts operate on the fulcrum principle. On a forklift, the fulcrum is located at the front tires.
PIT's operate on something called the FULCRUM principle. The fulcrum is the truck’s axis of rotation when it tips over.
Think about it like a seesaw…you have two weights that balance each other. With a forklift, one weight is the heavy rear end or counterweight and the weight of the truck. The fulcrum point in this case is the front tires, and the other weight is the load you’re carrying. The counterweight balances the load with the front tires as the fulcrum point.
If you tilt the mast forward when lifting, what are you doing to the load center? (You’re extending it forward, reducing the capacity as shown on the data plate).

12. 2) the load or object you are carrying
Center of Gravity
The center of gravity is where all of the weight is concentrated. Consider the center of gravity of the following:
1) the forklift itself
2) the load or object you are carrying
3) the combined weight of the load and the forklift together

13. Vehicle Stability During a tipover:
Stay with vehicle and lean away from direction of fall
Don’t jump downward while truck is tipping
Keep load at lowest practical point

14. Combined Center of Gravity
Stability Triangle B A
Combined Center of Gravity
Stability Triangle - All PIT’s, whether they have three wheels for four, have something called the “pivot point”. Since forklifts don’t have shock absorbers, the pivot pin supports the forklift’s rear end. This allows the up and down movement of the rear tires when traveling over bumps and uneven surfaces.
The pivot pin and the front tires make up the three point suspension system; this three point suspension system forms an imaginary triangle called the “stability triangle”. When the combined center of gravity (CCG) of the load and truck falls within the stability triangle, the vehicle is stable and will not tip over. Sharp turns will cause the CCG to shift to the side; if the CCG falls outside of the stability triangle, the vehicle may tip over sideways. C
The pivot pin in the rear (A) and the two front tires (B and C) form the stability triangle on a forklift. As long as the combined center of gravity remains within this area, the forklift will not tip over.

15. Stability Triangle A B C
Vehicle Center of
Gravity (Unloaded)
Center of Gravity
of Vehicle and
Maximum Load
(Loaded)
As the forklift picks up a load, the center of gravity shifts towards the forks. If the load exceeds the maximum lifting capacity, the forklift will tip forward. If the load is lifted too high, the forklift may tip forward.
When the vehicle is loaded, the combined center of gravity (red circle) shifts toward line B-C.

16. Standard Load Center B C A
24"
Load Center is measured from the vertical face of the forks (or mast) to the center of the load. For example, if you have a standard pallet (48" x 48") and the load is evenly distributed, your load center is 24". Most PIT's specify your maximum load capacity at 24" load center.
Most forklifts specify the maximum load capacity based on a 24” load center. The load center is measured from the vertical face of the forks to the middle of the load.

17. Longitudinal Stability
For example: lifting a load that exceeds the maximum lifting capacity.
Longitudinal stability is the forklifts’ resistance to overturning frontward or backward.
Longitudinal stability - is a fancy word that means the truck’s RESISTANCE TO OVERTURNING forward or rearward.
A very short forklift would have less longitudinal stability than a very large or long forklift.
The forklifts’ axis of rotation is the front tires.
For example: tipping backwards while going up an incline.

18. Lateral Stability
Lateral stability is the forklifts’ resistance to overturning onto it’s side.
For example: turning a curve too fast or too sharp.
Lateral stability is the truck’s RESISTANCE TO OVERTURNING sideways.
A wide track vehicle has much greater lateral stability than a much narrower type of forklift.
Track is simply the distance between wheels on the same axle.
Wheelbase is the distance between the front and rear axles of the vehicle.
For example: an unstable load shifting to the left or right.

19. Dynamic Stability
Dynamic stability refers to the stability of the forklift while moving.
The faster you go, the more unstable you become!
Dynamic stability is simply the stability of the vehicle while it’s moving with a load.
-how fast
-making turns
-traveling on grade

20. What are the potential hazards
Forklifts steer from the rear.
Inclines / Wet surfaces
Loads will affect weight and balance.
Some Forklifts weigh 2-3 times more than a car.
Stability may be a concern.
Pallet truck vs Rider Truck
Refueling
Battery Charging
Steering: PIT's steer from the rear - watch out for rear end swing. Spinner knobs are NOT okay unless they’re approved by the manufacturer because they help you turn quicker and more sharply. This is not a good idea for a PIT.
Loads: remember, you're balancing and moving a load. If the load blocks your view, you should drive in reverse or use a spotter - always look in the direction of travel!
Weight: the average car weighs 3,000 pounds; a 6,000 pound capacity PIT weighs about 12,000 pounds!
Stability: we'll talk more about the center of gravity and stability of PIT's later; this issue is a big concern.
Refueling: depending on what type of PIT you have, refueling will cause additional hazards.
Different types of tires.
Speed
Attachments- Barrel Clamp

21. Make sure charging area is well ventilated.
Battery Charging-
Make sure charging area is well ventilated.
No smoking or open flames.
Wear proper protective equipment.
Turn off cables before connecting.
Check water level.
Charging area should be well ventilated. With some older batteries, the manufacturer may require that the vent caps be removed during charging, so check your owner’s manual!
No smoking or open flames! When a battery is charged and discharged, it produces hydrogen gas which is very flammable. A spark or open flame can cause the battery to explode.
What types of PPE should one wear?
-safety goggles (minimum) preferably under a face shield
-may also need acid resistant gloves
-protective apron if you are removing or performing
maintenance on a battery
Turn off the charging cables when connecting or dis- connecting them to prevent a spark that could cause an explosion.
The water level should be just above the battery plates.
If you spill acid, you should neutralize it with baking soda.
Leave vent cap on while charging.

22. Exposes workers to hazardous chemicals
Fueling / Charging of Batteries
Exposes workers to hazardous chemicals
Involves electrical hazards, heat build-up, generation of gas
Be aware of all hazards involving fueling
and battery handling

23. Turn off the forklift before fueling/ recharging.
No smoking or open flames in the area
Wear gloves for battery refueling
Wear eye protection & shield for splash hazards.
What type of PPE should you use when refueling propane? Gloves (propane is cold) and safety glasses.
Also, be aware that you can only store certain amounts of gas, propane or diesel inside of building. In most locations, you may only store 25 gallons or less inside of a building, outside of an approved fire area or storage room. Gas and diesel must be stored in approved safety cans - these have self-closing, self venting lids.
It is recommended that propane tanks be exchanged one to one and not stored on the premises unless necessary. Contact EHSS Fire Safety at (540) for specific storage requirements.
Have a fire extinguisher nearby

24. What type of tires does your forklift have?
Types of Tires
Solid tires
for asphalt and concrete surfaces
Pneumatic tires
for gravel roads or all-terrain
Different types of PIT’s may have different tires. These affect how the vehicle handles and where it can be operated.
Solid tires - can only be used on asphalt or concrete surfaces, otherwise, tires will become damaged and increase the instability of the PIT, or they may sink into soft terrain, causing a tip over.
Pneumatic tires - can only operate on asphalt, concrete or improved surfaces like gravel roadways. Again, be aware of soft terrain. (They do make specialized PIT’s that have all terrain tires.)
Identify what type of tires your forklift has at this time and discuss travel location limitations as indicated above.
What type of tires does your forklift have?

25. Workplace Hazards
Pedestrians may not be aware of how a forklift handles – braking, rear end swing –Give them the right of way.
Pedestrians! Most people aren’t aware of how a PIT handles (braking, swing, load stability, etc.) and THEY have the right-of-way!

26. Workplace Hazards
Surface conditions: Pot holes, false floors, weight limits, and wet floors can all affect your stability and/or braking distance.
What about surface conditions? (Potholes, speed bumps, wet surfaces, floor plates which may not hold the PIT)

27. Workplace Hazards What are you hauling?
If there is a spill, is it safe for you to clean it up, or should the building be evacuated?
If you will be hauling drums of chemicals, you should know what you are hauling, what health and safety concerns to be aware of in the event of a spill or accident, and where to find this information (on the Material Safety Data Sheet accompanying the chemical or in your MSDS book).
It is also important to secure the drums during movement!
Refer to the Material Safety Data Sheet prior to hauling the material.

28. Avoid driving too close to the edges of loading docks.
Trailer wheels must be chocked and truck brakes applied.
Dock plates:
Know the capacity.
Good condition?
Properly placed?
Secured?
Keep away from the edges of docks and ramps!
If you’re unloading a trailer:
-Trailer wheels MUST be chocked and the trucks parking brake must be set.
-Dock plates must have enough capacity and must be properly placed.
-If using mobile plates, check their position often…they will shift was you cross over them repeatedly. The trailer may also shift as you enter and exit, so keep an eye on its’ position. Dock clamps are highly recommended (these are clamps that secure the trailer to the dock.
Check the condition of the floor inside the trailer. It should be in good condition have enough capacity for both your PIT and the load.
Do you have ramps or docks in your work area? Do you load/unload trailer trucks?
Dock Plate

29. Speeding is the number 1 violation regarding forklifts
Safe Operating Procedures
Speeding is the number 1 violation
regarding forklifts
Forklifts and speed
– 3 mph, or about walking pace, is expected
Excessive speeding is the #1 violation on PIT's.
Stopping quickly while carrying a load may result in the load falling forward off forks; you may overcome the longitudinal stability of the PIT, causing it to tip forward.
Stopping on wet surfaces may reduce friction-taking longer to stop and increase the chances of skidding. If you hit a pothole or bump, what could happen?

30. Safe Operating Procedures
Cross bumps at an angle - slowly!
Travel with load at low safe level-visibility
Look in the direction you’re traveling
Sound horn at blind corners to warn others

31. Safe Operating Procedures
Riders are not allowed!
Wear your seat belt!
It will keep you within the forklifts’ rollover protection system
Riders are NOT allowed unless using an attachment approved for this use. The cage must be secured to the forks, have a 42 inch guardrail system, have a barrier in the rear to protect the rider from the mast, and operator's must remain at the controls at all times.
Always wear the seatbelt if one is provided (if the forklift came with a seatbelt, it must not be removed and it must be worn). This will keep you inside the rollover protection in case you tip over. If the forklift did not come with a seatbelt, grab the steering wheel and brace yourself with your arms against the steering wheel and your feet against the floor and your back against the back of the seat. Do not attempt to jump off of the forklift if it begins to tip over. You cannot jump faster that the forklift turning over!

32. Safe Operating Procedures
Parking:
Lower forks to ground
Set the brake
Put the controls in neutral
Remove the key if you will be more than 25’ from the forklift and public access is possible.

33. Safe Operating Procedures
Never exceed the forklift’s Maximum Lifting Capacity.
Remember – attachments used on the forklift will affect the Maximum Lifting Capacity.

34. NO HORSEPLAY is allowed! Always slow down when turning.
Safe Operating Procedures
NO HORSEPLAY is allowed!
Always slow down when turning.
Make sure the load is stable and won’t
shift while moving.
Always spread forks as wide as possible
for maximum stability.

35. Always keep arms and legs inside the roll over protection system.
Safe Operating Procedures
Don’t pick up loads on broken pallets or boxes in bad condition. Transfer the load to a new pallet or box before lifting.
Always keep arms and legs inside the roll over protection system.
Slow down when approaching cross aisles, ramps, dips, uneven or slippery surfaces and congested areas.

36. Inspection & Maintenance
Horn (safety feature)
Fluids (water, fuel, oil, hydraulics, transmission, electrolyte)
Brakes - operating and parking
Steering -- too much play in the steering wheel can be dangerous (2-3" is excessive)
Forks - look for cracks in the welds or anything else that could affect the integrity of the forks
Inspect mast chain
Raise and lower the mast - helps to lubricate the mechanism and cylinders, but be sure you have enough overhead clearance before you raise them all of the way
Safety equipment - seatbelt, lights, guards
Corroded battery components
Worn or cracked tires
Broken gauges or mirrors
Worn parts
Damaged mast or carriage
LP tank secure
If you find something that is not working, the vehicle must not be used. Repairs may only be made using parts approved by the manufacturer! What are some other components of a forklift?
*See the Operator’s Manual for specific inspection criteria.

37. Inspection & Maintenance
Forklift maintenance should be conducted per the manufacturer’s recommendations.
A daily inspection should be conducted prior to each day’s use.
Remove the forklift from service until proper repair or replacement can be made if defects are found

39. Back-up alarms must be audible and working.
Other Safety Considerations
Fire extinguishers (if provided on the forklift) must be charged and ready to use.
Back-up alarms must be audible and working.
It is recommended that there be a fire extinguisher kept on all powered industrial trucks, or that one be readily available in the work area. Certainly there needs to be a fire extinguisher at the refueling or charging location!
If your PIT has back-up alarms, directional lighting, and/or flashing lights, these must be kept in good repair and used as required by the Owners Manual.
If you must operate your PIT on highways/near traffic, make sure you have the appropriate warning/hazard signs on the PIT, and that the PIT has signal controls (or you must use hand signals).
Be aware of any Administrative practices- ie. policies related to forklift safety

40. Operational Training
Know where controls are located, what they do, how they work
Inspection test
Obstacle course / Routine function testing

41. Operational Training
Design a course that incorporates a series of tasks that would be require the operator to repeat the most difficult tasks that he/she would be required to carry out on the lifttruck (including pre-trip inspection and control manipulation)
Operational trainer should be most experience lift operator with a proven good safety rating
Trainer should walkthrough a pre-trip inspection and the “how to” use vehicle controls

42. Certification Operations and Classroom Evaluations:
Pass = Certification
Name of the Operator
Date of Training and Evaluation
Name of Trainer
Listing of material covered

43. Lawn Mowers- Considerations
(Riding Mowers) Same Requirements as forklifts plus design standards (e) (consumer type mowers)

44. Lawn Mowers- Considerations
(e)(1)(i) Power lawnmowers of the walk-behind, riding-rotary, and reel power lawnmowers designed for sale to the general public shall meet the design specifications in
"American National Standard Safety Specifications for Power Lawnmowers" ANSI B71.1-X1968, which is incorporated by reference as specified in Sec

45. Lawn Mowers- Considerations
(e)(1)(iii) A shutoff device shall be provided to stop operation of the motor or engine.
(e)(1)(iv) All positions of the operating controls shall be clearly
(e)(1)(v) The words, "Caution. Be sure the operating control(s) is in neutral before starting the engine,"

46. Lawn Mowers- Considerations
According to Consumer Product Safety Commission (CPSC), 25,300 people are injured by lawn mowers each year:
75 are killed
Two most common injuries: amputations and injuries from thrown objects
The speed of debris coming out of the discharge chute has been clocked at 200 miles per hour
Push mower should be mowed across a slope; riding mower up and down a slope

47. Lawn Mowers- Considerations
Know how to operate equipment - Read owner’s manual. Know where controls are and what they do
Dress properly - Wear long pants, safety shoes, and safety glasses (Hearing protection)
Handle gas carefully - Fill up while engine is cold. Don’t spill when you fill. Store gas in approved container in cool ventilated area. Never smoke around gasoline
Clear area before you start - Pick up rocks, twigs, cans hoses, anything that can be thrown by mowing equipment
Follow recommended procedures - Always turn off engine and disconnect spark plug before unclogging or working on equipment
Keep hands and feet from moving parts - Never remove or tamper with safety devices or labels. They are for your protection