Forklift Operator Training OSHA 1910.178 Powered Industrial Trucks

Developed by HMTRI through cooperative agreement # 2 U45 ES006177-14 with NIEHS under the Worker Safety and Health Training

Support Annex

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Objectives of this training - At the end of this session, you should be able to:

1. Identify the hazards involved with Powered Industrial Trucks (PITs)

2. Explain the different types of PITs

3. Conduct a PIT visual inspection

4. Pass the written test5. Demonstrate proficient

operator skills on a forklift

OSHA 1910.178 Powered Industrial Trucks -Operator Training

1910.178 (l)1910.178 (l)1915.120 (a)1915.120 (a)1917.1 (a)(2)(xiv)1917.1 (a)(2)(xiv)1918.1 (b)(10)1918.1 (b)(10)1926.602 (d)1926.602 (d)

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Powered IndustrialTruck - Definition

• A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]

• Excluded are vehicles used for earth moving and over-the-road hauling.

• Commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lifttrucks.

• Can be powered through electric or combustion engines.

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Performance-Oriented Requirements

• The powered industrial truck operator training requirements are performance-oriented to permit employers to tailor a training program to the characteristics of their workplaces and the particular types of powered industrial trucks operated.

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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 (or previously received appropriate training).

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Training Program Implementation

• Trainees may operate a powered industrial truck only:– Under direct supervision of a person who has

the knowledge, training, and experience to train operators and evaluate their competence; and,

– Where such operation does not endanger the trainee or other employees.

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Training Program Implementation (continued)

Training shall consist of a combination of:Training shall consist of a combination of: Formal instruction (e.g., lecture, discussion, Formal instruction (e.g., lecture, discussion,

interactive computer learning, written material), interactive computer learning, written material), Practical training (demonstrations and exercises Practical training (demonstrations and exercises

performed by the trainee), and performed by the trainee), and Evaluation of the operator’s performance in the Evaluation of the operator’s performance in the

workplaceworkplace

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Training Program Implementation (continued)

• 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.

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Training Program Content• Operators shall receive initial training in

the following topics, except in topics which the employer can demonstrate are not applicable to safe operation in the employer’s workplace. – Truck-related topics– Workplace-related topics– The requirements of the standard

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Training Program Content (continued)

– Operating instructions, warnings and precautions

– Differences from automobile

– Controls and instrumentation

– Engine or motor operation– Steering and maneuvering– Visibility

Truck-related topics– Fork and attachment

adaptation, operation, use – Vehicle capacity and stability– Vehicle inspection and

maintenance that the operator will be required to perform

– Refueling/Charging/ Recharging batteries

– Operating limitations– Other instructions, etc.

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Training Program Content (continued)

– 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

– Potentially hazardous environmental conditions

– Operating in closed environments or other areas where poor ventilation or maintenance could cause carbon monoxide or diesel exhaust buildup

Workplace-related topics

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

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Refresher Training and Evaluation (continued)

• 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

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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

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Appendix A - Stability of Powered Industrial Trucks

• Definitions• General• Basic Principles• Stability Triangle• Longitudinal Stability• Lateral Stability• Dynamic Stability

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A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Theoretical)

Stability Triangle - Figure 1

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.

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Load CG

Vertical StabilityLine(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical StabilityLine(Line of Action)

Truck CG

The vehicle is stable This vehicle is unstable and will continue to tip over

Stability Triangle - Figure 2

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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 hazards of workplaces generally; and,– The hazards of the particular workplace

where the vehicle operates.

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Types of Powered Industrial Trucks

• There are many different types of powered industrial trucks covered by the OSHA standard.

• Commonly used types include:– High lift trucks, counterbalanced trucks, cantilever trucks,

rider trucks, forklift trucks, high lift trucks, high lift platform trucks, low lift trucks, motorized hand trucks, pallet trucks, straddle trucks, reach rider trucks, high lift order picker trucks, motorized hand/rider trucks, and counterbalanced front/side loader lift trucks.

• A single type of truck can only be described by calling it by all of its characteristics, (e.g., a high lift, counterbalanced, sit down rider truck).

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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.

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A PIT is a PIT NOT a CAR

Controls are different from those of cars. Steer very differently than cars. Are used for different purposes than cars. Steer from the rear, and have drive wheels in the

front. When turning, the rear end swings in a circle. Front drive wheels support most of the load. Less steering control when turning, especially if

loaded. Difficult to stop quickly and dangerous to swerve.

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Components of a Forklift Truck*

*One of the most common types of powered industrial trucks

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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

* Note that this classification refers to commonly-used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

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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)

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Class I - Electric Motor Rider Trucks

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

Fork, counterbalanced (cushion/solid tires)

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

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Class V - Internal Combustion Engine Trucks - Pneumatic Tires

Fork, counterbalanced (pneumatic tires)

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Class V - Internal Combustion Engine Trucks (Pneumatic Tires)

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Must be done at least daily or at the beginning of each shift

Check the power-plant

Gas, Diesel or Propane Powered

Electric Powered

Check for damage and proper operation.

Pre-use Inspection

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Performance DataGross vehicle weight without a load will

always exceed the vehicle’s rated lifting capacity

Gross vehicle weight will normally be about 2 times the vehicle’s rated capacity

Weight distribution varies depending on load weight and position

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NEVER EXCEED the rated load capacity of your PIT

Look for Impact or Capacity plate to find: >machine working capacity>gross vehicle weight>rated load center >capacity rating with attachment>tire data>attachment identification>maximum lift height

Load Stability

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Reduce your load if:The load is too tall, wide, oddly shaped or if

you are using attachments.A high lift is involved or if the route is rough.The load can’t be centered on the pallet or

carried close to your drive wheels.You have to make tight turns or travel on a

ramp or slope.

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To Keep the Load Stable:Space your forks as far apart as possible.Make sure the load won’t shift while

traveling.Secure loose or slippery items.Transfer loads on broken pallets to sound

pallets before picking them up. Wrap or strap loads made up of individual

items.

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Load Capacity

AttachmentsBatteriesWhen in doubt consult your supervisor

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Stability in PracticeYour PIT and load become less stable in

any of the following situations:– whenever the load is raised

– when you are turning

– on slopes, either front to back or side to side

– when tilting the load forward or backward, or side to side

– on rough or uneven surfaces

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Center of Gravityand Stability Triangle

Center ofGravity

Drive Tires

Center of Steering Axle

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Center of Gravity Will Shift

STATIC FORCES are affected by:

a) load characteristicsb) lift heightc) amount of tiltd) tire condition

DYNAMIC FORCES are affected by:

a) accelerationb) travel speedsc) brakingd) surface condition

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Counterbalance

load is carried at front of vehicle and is offset or counterbalanced by the weight of the vehicle located behind the drive tires which act as a pivot point internal combustion-engine, steer axle,

transmission, counterweight, and frame electric powered battery, control panel,

motors and pumps, steer axle, counterweight, and frame

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Some Questions to Help Judge a Load:

What is the rated load capacity of my truck? Is this load well within the capacity limits? Will the shape of this load affect my stability? Will the load affect my visibility? Do I need to split up the load? Do I need to drive in reverse? What hazards are along the route? ?

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Some Questions to Help Judge a Load:

What turns will I have to negotiate? Are there ramps, slopes, rough ground or

obstacles? What about the destination? Can I get close enough? Can I pull straight in? Is the area free of overhead hazards like

power lines, pipes or ventilation equipment?

?

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Principles of Internal Combustion

Fuel TypeEngine Starting ConditionsRefuelingChanging an LP Tank

Gasoline

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Principles of Electric Battery Power

Three Primary Voltage TypesRecharging a Battery

– Trained Personnel ONLY– SOPs– PPE– Designated Areas ONLY

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Maintenance of PITs

If defective, take out of serviceRepair by authorized personnel onlyRepair parts as safe or safer than originalDo not alter from manufacturer’s designRepair in designated location

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Safe Parking Procedures

How and Where to Park?Attended ParkingUnattended ParkingParking on an incline

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Lifting a Load Level the forks and slowly drive

forward until the load rests against the mast.

Do not slam a load into the carriage.

Lift the load high enough to clear whatever is under it.

Assess the stability of the load. Tilt the mast back slightly to a

traveling position.

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Lifting a Load If there is another load in front of yours, lift

without tilting. Reassess load stability. Look over both shoulders to make sure it is

safe to move in reverse. If there are no obstacles to the rear, back out

slowly about one foot to insure the load will clear.

Back away to completely clear the load. Lower load to travel and reassess load stability.

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Carrying the Load

Keep your vehicle under control at all timesKeep forks close to floor Maintain safe distance (3 vehicle lengths)Examine surfaces - safety and strengthSafe speed - a brisk walking pace

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Carrying the Load Stay within the vehicle lanes. Look over both shoulders before you back up. Stop before raising or lowering loads. Tilt the load slightly back with forks low. Drive at a slow, steady pace. Observe speed limits and controlled Slow down for turns, sound your horn and stay

near the inside corner.

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Carrying the LoadSlow down and sound your horn at

intersections and places with limited view.Drive in reverse if your vision is obstructed

by your load.Yield to pedestrians - always!!!

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Carrying the Load

Never travel or turn with the load elevated.

Never drive up to anyone standing in front of a fixed object.

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Carrying the Load Never allow anyone to stand on your fork or

lift people without an approved platform.

Never allow anyone to walk or stand under your forks, whether the forks are loaded or empty.

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Carrying the Load

Surfaces you should avoid or be very careful on or around include: – Loose objects, bumps or uneven floors

– Rough surfaces

– Wet, oily or icy surfaces

– Railroad tracks and similar edges, which you should cross at a 45-degree angle whenever possible

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Putting Down a Load

Square up and stop about 1 foot away from the loading area

Drive about 1/2 way into the unloading areaLower the load, assess alignment, stabilityLower forks slightlyLook over both shoulders and back out

slowly

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Working with StacksThe higher you go - the less stable

your PIT and load

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Working with Stacks

Remember these stacking rules:

– Set the top load squarely on the stack

– Never raise or lower a load unless you fully stop

– Never attempt to turn with your mast raised

– Approach load straight on and back straight out

– Make sure you have enough overhead clearance

– Watch for electrical lines, pipes, fixtures, sprinklers

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Traveling on Grades

Stay well back from the edge Never turn around on the slopeDrive with your load on the uphill side!!!

– When loaded, drive up slopes with your load in front and drive down slopes in reverse.

– When the forks are empty, back up a slope and drive down it forward.

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Working on Docks DOCK WORK CHECK SHEET

Check to make sure that wheels are chocked!

Check the front support on a trailer to insure it won’t shift.

Check to make sure the train car or trailer brakes as set.

Check the dock locks.

Check the deck capacity.

Check combined vehicle and load weight.

Check dock plate condition and position.

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In Case of a Tip-over

Do not jump from the unit! HOLD ON TIGHT

BRACE YOUR FEET

LEAN AWAY FROM THE TIP DIRECTION

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Summary

• Operating a Powered Industrial Truck is a highly skilled job that is dangerous if not done properly.

• You need to know all about your PIT and its operation including:– design and function – controls and instruments– pre-use inspection– stability– capacity and visibility