Forklift Operator Training OSHA 1910.178 Powered Industrial Trucks

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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

• Identify the hazards involved with Powered
  Industrial Trucks (PITs)
• Explain the different types of PITs
• Conduct a PIT visual inspection
• Pass the written test
• Demonstrate proficient operator skills on a
  forklift

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OSHA 1910.178 Powered Industrial Trucks
-Operator Training

• 1910.178 (l)
• 1915.120 (a)
• 1917.1 (a)(2)(xiv)
• 1918.1 (b)(10)
• 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
• Formal instruction (e.g., lecture, discussion,
  interactive computer learning, written material),
  
• Practical training (demonstrations and exercises
  performed by the trainee), and
• Evaluation of the operators performance in the
  workplace

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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 employers workplace.
• Truck-related topics
• Workplace-related topics
• The requirements of the standard

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Training Program Content (continued)

• Truck-related topics

• Operating instructions, warnings and precautions
• Differences from automobile
• Controls and instrumentation
• Engine or motor operation
• Steering and maneuvering
• Visibility

• 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)

• 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
• Potentially hazardous environmental conditions
• Operating in closed environments or other areas
  where poor ventilation or maintenance could cause
  carbon monoxide or diesel exhaust buildup

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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
  operators 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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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.
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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
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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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Pre-use Inspection

• 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.

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Performance Data

• Gross vehicle weight without a load will always
  exceed the vehicles rated lifting capacity
• Gross vehicle weight will normally be about 2
  times the vehicles rated capacity
• Weight distribution varies depending on load
  weight and position

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Load Stability

• NEVER EXCEED the rated load capacity of your PIT
• Look for Impact or Capacity plate to find
• gtmachine working capacity
• gtgross vehicle weight
• gtrated load center
• gtcapacity rating with attachment
• gttire data
• gtattachment identification
• gtmaximum lift height

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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 cant 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 wont 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

• Attachments
• Batteries
• When in doubt consult your supervisor

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Stability in Practice

• Your 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
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Center of Gravity Will Shift

• STATIC FORCES
• are affected by
• a) load characteristics
• b) lift height
• c) amount of tilt
• d) tire condition

• DYNAMIC FORCES
• are affected by
• a) acceleration
• b) travel speeds
• c) braking
• d) 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 Type
• Engine Starting Conditions
• Refueling
• Changing an LP Tank

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Principles of Electric Battery Power

• Three Primary Voltage Types
• Recharging a Battery
• Trained Personnel ONLY
• SOPs
• PPE
• Designated Areas ONLY

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Maintenance of PITs

• If defective, take out of service
• Repair by authorized personnel only
• Repair parts as safe or safer than original
• Do not alter from manufacturers design
• Repair in designated location

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Safe Parking Procedures

• How and Where to Park?
• Attended Parking
• Unattended Parking
• Parking 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 times
• Keep forks close to floor
• Maintain safe distance (3 vehicle lengths)
• Examine surfaces - safety and strength
• Safe 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 Load

• Slow 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 area
• Lower the load, assess alignment, stability
• Lower forks slightly
• Look over both shoulders and back out slowly

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Working with Stacks

• The 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 slope
• Drive 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
  wont 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