2. Powered Industrial Trucks Safe Operations

3. Classes of Commonly-Used 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

4. Unique Characteristics of Powered Industrial Trucks
Each type of powered industrial truck has its own unique characteristics and some inherent hazards.
To be effective, training must address the unique characteristics of the type of vehicle the employee is being trained to operate.

5. ... truck controls and handling are different
Forklift Training
You must also have hands-on training on the specific truck you will be operating
... truck controls and handling are different

6. Powered Industrial Trucks
Forklifts are extremely useful in a variety of workplaces, but there is great risk of property damage, injury or death if you:
are not trained on forklift safety
- are not familiar with the specific forklift vehicle
- operate the forklift in an unsafe manner
- operate a forklift with a defect or missing parts
Because the cause of so many forklift accidents is lack of proper training, this training is required by L & I regulations for any person who will using a forklift.

7. Forklift accident statistics
85 to 100 workers in the U.S. are killed every year in forklift accidents.
Fatal Accident Type
Per Cent
Crushed by vehicle tipping over
42%
Crushed between vehicle and a surface
25%
Crushed between two vehicles
11%
Struck or run over by a forklift
10%
Struck by falling material 8%
Fall from platform on the forks 4%
Approximately 35,000 serious injuries and 62,000 non-serious injuries involving forklifts occur in the United States every year. OSHA estimates 11% of all forklifts are involved in accidents every year.

8. Common Engineering Principles
Front
FORKLIFT
Steering Axle
DIFERENCES
The steering axle is in the back
It has only three support points
It´s narrower
The CG area is smaller
Back
Front
CAR
Steering Axle
DIFERENCES
The steering axle is in front
It has four support points
Its wider
The CG area is larger
Back

9. Differences
Pivot
point
AUTOMOBILE
FORKLIFT

10. Center of Gravity How the Center of Gravity (CG) moves: Without load
With load, the CG moves forward
With load raised, the CG moves upward
With load raised and mast leaning forward, the CG moves forward

11. V.C.O.G. Combined Center of Gravity C.C.O.G. L.C.O.G.
Vehicle center of
Gravity ( Unloaded)
V.C.O.G.
Combined Center
of Gravity
C.C.O.G.
Load Center
Of Gravity
L.C.O.G.
6,000 LB LOAD
C.O.G.
4.000 LB TRUCK
VECHICLE
4,000 LB LOAD
C.O.G.
4.000 LB TRUCK
VECHICLE
FULCRUM POINT

12. Handling and Moving Loads
Check the Capacity Plate to be sure the forklift can handle the load
Check the load for weight and stability
Weight
Type
Load
capacity
This forklift is a propane (LP) powered forklift, weighing 8680 lbs. with a lifting capacity of up to 4500 lbs.

13. Load Position
The same 4500 pounds weight loaded properly will exceed the rated capacity of 4500 pounds if the rectangular box is positioned lengthwise .
Forklifts are designed to carry a capacity load at a standard load center, commonly 24 inches
Load weight, weight distribution, size, shape, and position are key factors affecting the stability of the forklift.

14. Safe Operation
Only trained and authorized personnel are allowed to operate
Always keep all body parts inside the running lines of vehicle.
Always wait until vehicle comes to a complete stop before dismounting.
Start and stop vehicles slowly and smoothly

15. Operating the Forklift
Know locations and functions of all controls and gauges
Be aware of what is going on around you
Be aware of potential problems with the forklift
Be sure path of travel is free from hazards
Traveling speed in doors should not be any faster than a quick walking pace

16. Safe Forklift Operations
Keep hands, arms, head and legs inside the running lines or roll-over protection structure
Never raise people on the forks
Always sound your horn at intersections
Be aware of overhead obstructions

17. Keep the load against the backrest (mast) as much as possible.
Traveling
Keep the load against the backrest (mast) as much as possible.
When traveling on level surfaces the forks should not be raised more than about 4”-6” from the floor or ground.
When on unlevel surfaces, the forks should not be raised any higher than necessary to clear the ground.
Travel should be smooth, slow, cautious and the operator must always look in the direction of travel before beginning to move.
Forklifts must never be driven up to someone standing in front of a bench or other fixed object
Read the slide

18. Traveling Always look in the direction of travel
When moving, the mast must not be raised
Sound the horn
Operate at safe speeds
Check clearance under overhead installations
I. Speaker’s Notes:
Remember to always look behind you before backing up.
The cage is there to protect your body.
Many operators have a bad habit of moving while raising or lowering a load. This can cause an unstable situation and a possible tipover.
Sound the horn at corners, crossing aisles, near doorways, etc.
A safe speed is a speed at which you can quickly and easily stop if a pedestrian steps out in front of you.
Remember, the forklift steers from the rear, so be careful when turning because the rear end swings wide.
Watch for overhead installations when lifting your load.

19. Operating Speeds Hazards associated with operating speeds include:
Tipovers caused by driving too fast
Collision with pedestrians, other vehicles, or objects when changing directions
Falling loads following a collision
Collisions may occur when:
Approaching too fast
Turning too rapidly
Failing to slow for wet or slippery conditions

20. Driving on an incline
Always drive with the load on the uphill side - go backwards driving down the incline and frontwards going up the incline to prevent tipping or losing control of the forklift.
If no load on the forklifts, do the opposite with forks pointing down the ramp

21. Safe Forklift Operations
Use lights when working in trailer
Make sure trailer wheels are chocked
When parking a forklift
Do not block aisles, doorways, fire exits
Do not park in travelways or work locations
Lower forks to the floor – do not leave trip hazards

22. Forklift Attachments
Forklifts can have a variety of attachments which affect their performance and use.
The load capacity of the forklift is reduced by the weight of the attachment.
The attachment must be approved by the forklift manufacturer.
Be sure you know how to use the specific attachment on the forklift you will be operating.

23. Surface Conditions Loading Docks Slippery Conditions: Ice, Water
Stop and remove any obstruction, pieces of broken pallets or debris.

24. Yield right of way to pedestrians.
Pedestrian Traffic
Yield right of way to pedestrians.
When a person or group of people walk across your planned route:
Stop traveling
Wait until the pedestrians pass by
Proceed cautiously through any congested area

25. Operator must do all of the following prior to starting a forklift:
Truck Inspections
Perform pre-start visual check with keys off
Perform operational check with engine running 
Determine if forklift is safe to operate
Complete required documentation
Lock out unsafe lifts as determined in a pre-operation inspection
Operator must do all of the following prior to starting a forklift:

26. Report All Defects
Remove from service any truck not in a safe operating condition
Immediately report all defects
Delaying needed maintenance causes breakdowns and injuries
Examine industrial trucks before placing in service
Where industrial trucks are used on a round-the-clock basis, inspect before each shift
Inspect each vehicle before use

27. Safe Operations of Forklifts
Always have control of your equipment and focus on preventing any type of unsafe conditions.
Safety benefits everyone, but most importantly…You!
QUESTIONS?