1. Powered Industrial Trucks Class IV Operator Training
OSHA General Industry Standards
(Yard/Warehouse Forklifts).
OSHA Construction Standards
(Separate Training and Certification)(Off Road Jobsite Forklifts).
ANSI B

2. 3 Short Video Clips
PIT FLIPPING
STAY WITH THE TRUCK
CLEARANCE

3. 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.

4. Powered Industrial Truck Accident Stats
Type of incident % victims killed by this type of incident
Forklift overturns
Worker struck by forklift 20
Victim crushed by forklift 16
Fall from forklift
*IMPORTANT – ALWAYS WEAR YOUR SEATBELT WHILE OPERATING A FORKLIFT.
BUREAU OF LABOR STATISTICS

5. 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.

6. Training Program Content
Truck-related topics
Operating instructions, warnings and precautions
Differences from automobile
Controls and instrumentation
Engine or motor operation
Steering and maneuvering
Visibility
Vehicle capacity and stability
Vehicle inspection and maintenance that the operator will be required to perform
Operating limitations

7. 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 (

8. Training Program Content (continued)
Workplace-related topics
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

9. 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

10. Operator Training Video

11. Components of a Forklift Truck*

12. 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.

13. Stability Triangle - Figure 1
Vehicle Center of
Gravity (Unloaded) B A
Center of Gravity
of Vehicle and
Maximum Load
(Theoretical) C
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.

14. Never travel with a raised load….

15. Operating On Ramps Or Inclines
Remember: Never turn on ramps or inclines, straight up and straight down.

16. Operating On Ramps Or Inclines
When descending a grade, stopping distance
will be greater than on-level operation. Methods shall be
provided to allow for this condition. Some methods are:
reduce speed, limit loads, allow adequate clear space at
the bottom of the grade, etc.

17. 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.

18. Side Stability Triangle - Figure 2
Load CG
Load CG
Vertical
Stability
Line
(Line of Action)
Combined CG
Combined CG
Vertical
Stability
Line
(Line of Action)
Truck CG
Truck CG
This vehicle is unstable and
will continue to tip over
The vehicle is stable
The vehicle is stable

19. Data Plate Information
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
Data Plate Location

20. Load Center
A 24 Inch 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.

21. 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

22. 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.

23. 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)

24. Do Not Enter or allow others to enter Pinch-Points

25. Eliminate the Pinch-Point

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

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

28. Do Not Enter Pinch-Point

29. Do Not Enter Pinch-Point

30. Do Not Enter Pinch-Point

31. Do Not Enter Pinch-Point

32. Do Not Enter Pinch-Point
This is the same issue as when loading a truck. The operator could have eliminated the pinch-point.

33. 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!!)

34. Travel Speeds INTERNAL COMBUSTION LIFT TRUCK: Top Speed - 9 MPH
ELECTRIC LIFT TRUCKS: Top Speed - 6 MPH
WALKIE PALLET TRUCKS: Top Speed - 3 MPH
FEET PER SECOND:
IC ’ per second
Electric ’ per second
Walkie ’ per second

35. Stopping Distances BRAKE REACTION TIME: YOUNG – Under 1 Second
OLDER – Over 1 Second (13 Feet)
BRAKE APPLIED STOPPING DISTANCE:
I.C Feet Electric Feet
TOTAL STOPPING DISTANCE:
I.C Feet ELECTRIC Feet

36. 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.

38. LEARNING EXAM (completed as group)

39. 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.

40. 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.

41. 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).

42. Drywall Wedge Insert the wedge manually at the proper location
Drywall Wedge Insert 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.

43. Drywall Wedge Push the wedge slowly into the lift of drywall using the tip of the fork.

44. Drywall Wedge Slowly drive into the drywall with the forks on each side of the wedge.

45. COVERS ON OVERHEAD GUARDS
PLYWOOD, CARDBOARD, OR ANY OTHER MATERIAL THAT THE OPERATOR CANNOT SEE THROUGH CLEARLY IS NOT PERMITTED AS A COVER.
THE OPERATOR MUST BE ABLE TO CLEARLY SEE THE LOAD UP THROUGH THE OVERHEAD GUARD.

46. 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.

47. 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.

48. 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)

49. Yard Hazards Potholes in parking lot Uneven pavement
Company Vehicle traffic
Other forklift traffic
Customer traffic
Pedestrians (employees & customers)
Weather/Environment

50. Hazard Identification

51. Hazard Identification

52. Hazard Identification

53. Hazard Identification

54. 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

55. Decals
What is wrong here?
Under OSHA (a) (6) The user shall see that all nameplates and markings are in place and are maintained in legible condition

56. Decal Definitions 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

57. 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.

58. Cell Phone Use
CELL PHONES ARE NOT PERMITTED WHILE OPERATING FORKLIFTS OR ANY OTHER EQUIPMENT.

59. HAZARDS Of Dock Operations!
Trailer Restraint
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
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.”

60. Dock Accident

61. Arms & Legs
Always keep your arms and legs inside the confines of the lift truck during operation!!

62. 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.

63. Symptoms of Carbon Monoxide Poisoning
Headache
Dizziness
Nausea
Vomiting
Chest Pain
Confusion

64. Safe Handling Of Fuels What Powers These Lift Trucks???? Gasoline
Diesel Fuel
LPG
Electric (Storage Battery)
Read And Follow All Warnings And Safety Guidelines When Handling Any IC Fuels Or Industrial Batteries.

65. 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.

66. 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.

67. 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

68. Storage Tank External Parts
Pressure Relief Valve
80% Fill Valve
Liquid Discharge Port
Vapor Discharge Port
Quick Fill Port
Fuel Gauge

69. Storage Tank Internal Parts
Vapor Withdrawal Tube
Fuel Level Float
Liquid Withdrawal Tube
80% Fill Tube

70. Proper LPG Tank Alignment
Alignment Holes
Properly Installed LPG Tank

71. Storage Tank Pressure Certification
Tank Manufactured Date
Can go 12 years from the manufacture date then the tank needs to be retested. If it passes, then you can go 7 years then retest again. If it passes, then you can go 5 more years. After that the tank needs to disposed.

73. Battery Hazards
The main hazards of lead-acid batteries are of four types:
1. Electrolyte
2. Gasses
3. Electricity
4. Battery Weight

74. Batteries Create, HYDROGEN GAS
Extremely Explosive!!!

75. Battery Cell Exploded

76. 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.

77. 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.

78. Battery Chargers High Amp Industrial Charger
Low Amp Single Shift Charger
Battery Charging Area With Ride On Battery Changer.

79. Weekend/Equalize Charge
Daily charge as needed
Equalize charge once per month on Friday evening
Charger Control

80. 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.

81. 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.

82. 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.

83. Sulfuric Acid First Aid Measures
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.

84. 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.

85. Sulfuric Acid First Aid Measures
Inhalation
If inhaled, remove person to fresh air and obtain medical treatment.

86. Oil Injected Into Hand
CAUTION-Do not use your HAND to check for leaks!

87. 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.

88. 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.

89. 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.

90. 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.

92. Final EXAM Read Each Question in Detail

93. 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).