1. Operating a Forklift safely
OSHA , ANSI B , NFPA By Ralph F Hall OHST

2. 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

3. 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.

4. 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.

5. 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).

6. 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

7. 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.

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. Class I - Electric Motor Rider Trucks

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

16. Class II - Electric Motor Narrow Aisle Trucks

17. Class II - Narrow Aisle Trucks

18. Class III - Electric Motor Hand or Hand/Rider Trucks

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

20. Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

21. Class VI - Electric & Internal Combustion Engine Tractors

22. Rough Terrain Straight Mast

23. Rough Terrain Extended-Reach Forklifts

24. 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.

25. 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.

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

27. 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

28. 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

29. 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

30. 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.

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

32. 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

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

34. 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!

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

36. 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

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

38. 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.

39. 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.

40. BATTERY FILLING PRECAUTIONS
DISTILLED
WATER
OK!

41. 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

42. 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.

43. 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

44. 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.

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

46. 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.

47. 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.

48. 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.

49. 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

50. 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

51. 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.

52. 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.

53. 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.

54. 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.

55. 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.

56. 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.

57. 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.

58. 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.

59. 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.

60. 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.

61. 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.

62. 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.

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

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

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

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

67. LONGITUDINAL TURNOVER
TURNOVERS
LONGITUDINAL TURNOVER
ACME
FORKLIFTS

68. TURNOVERS
LATERAL TURNOVER
ACME
FORKLIFTS

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

70. 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

71. 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.

72. 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

73. Using a Forklift is a privilege