OSHA 29CFR 1910.178

1. ACME PARTS CLARK FORKLIFT SAFETY (1999 REVISION) OSHA TRAINING OSHA 29CFR 1910.178

2. COURSE OBJECTIVES • Introduce Training and Regulatory Requirements. • Discuss Basic Forklift Operating Principles. • Discuss Forklift Safety Requirements. • Discuss the Different Types of Forklifts. • Discuss Hazardous Driving Situations. • Conduct a Written and Driving Proficiency Test.

3. STUDENT LEARNING OUTCOMES • Understand Safety Regulations Regarding Forklifts. • Understand Basic Forklift Operating Principles. • Understand the Hazards Involved With Forklifts. • Successfully Operate Forklifts Safely. • Successfully Complete a Written Proficiency Test. • Successfully Complete a Driving Proficiency Test.

4. ANSI STANDARD POWERED INDUSTRIAL TRUCKS ANSI American National Standard for Powered Industrial Trucks Part II, B56.1-1969

5. REGULATORY STANDARD POWERED INDUSTRIAL TRUCKS 29CFR - 1910 - 178 29CFR - Safety and Health Standards 1910 - General Industry 178 - Powered Industrial Trucks

6. FORKLIFT INJURY STATISTICS APPROXIMATELY 34,000 RELATED INJURIES A YEAR: • INATTENTION • DISTRACTION • EXCESSIVE SPEED • POOR DRIVING HABITS • LACK OF TRAINING

7. CIRCUMSTANCES OF INJURY 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.

8. CASE STUDY #1 CRUSHED AGAINST A STEEL POLE NARRATIVE: AN EMPLOYEE WAS SPOTTING A FORKLIFT BACKING UP IN A CONGESTED FLOOR AREA. THE OPERATOR ATTEMPTED TO EASE THE VEHICLE SLOWLY BACK TO GAIN CLEARANCE TO TURN. THE GAS PEDAL STUCK SLIGHTLY CAUSING THE VEHICLE TO LURCH, PINNING AND CRUSHING THE SPOTTER BETWEEN THE FORKLIFT AND A POLE RESULTING IN FATAL INJURIES. CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN A FIXED OBJECT AND THE VEHICLE.

9. CASE STUDY #2 KILLED BY TOPPLED FORKLIFT NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM A LOADING DOCK TRAILER TO A WAREHOUSE LOCATION WHEN THE VEHICLE WAS DRIVEN OFF OF THE SIDE OF THE DOCK RESULTING IN A LATERAL TIPOVER OF THE VEHICLE AND FATAL OPERATOR INJURIES. CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE EDGE OF THE DOCK AND THE VEHICLE.

10. CASE STUDY #3 KILLED BY TOPPLED FORKLIFT NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL FROM A STACKED PALLET STORAGE LOCATION TO THE WAREHOUSE FLOOR. THE OPERATOR BEGAN MOVING THE VEHICLE WITH THE LOAD EXTENDED BEFORE LOWERING THE LOAD, RESULTING IN A CENTRIFUGAL OVERLOAD AND TOPPLING. THE OPERATOR WAS CRUSHED BY THE VEHICLE. CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL

11. TRAINING REQUIREMENTS (1999 REVISION) HOW THIS COURSE IS STRUCTURED: • Classroom Lecture. • Supporting Audio/Video Aids. • Student Discussion/Interaction. • Field Discussion of Specific Vehicles. • Field Evaluation of Your Performance.

12. TRAINING REQUIREMENTS (1999 REVISION) MEASUREMENT OF OPERATORS PERFORMANCE: • You Will Be Given Training Specific to the Vehicle. • Your Performance Will Be Observed. • You Must Pass an Operating Performance Test. • You Must Pass a Written Performance Test.

13. TRAINEE REQUIREMENTS (1999 REVISION) TRAINEES MAY OPERATE A FORKLIFT ONLY: 1. Under the Direct Supervision of Persons Who Have the Knowledge, Training, and Experience to Train Operators and Evaluate Their Competence; And 2. Where Such Operation Does Not Endanger the Trainee or Other Employees.

14. TRAINEE REQUIREMENTS (1999 REVISION) TRAINEES MUST BE PROPERLY TRAINED: 1. Training Must Consist of a Combination of Formal Instruction (Lecture, Discussion, Video Tape, Written Material). 2. Practical Training (Demonstrations Performed by the Trainer) 3. Practical Exercises (Exercises Performed by the Trainee) 4. Evaluation of the Operator's Performance in the Workplace.

15. TRAINING REQUIREMENTS (1999 REVISION) TRUCK TOPICS TO BE ADDRESSED: • Operating Instructions. • Warnings, and Precautions. • Differences Between the Truck and the Automobile. • Truck Controls and Instrumentation. • Engine or Motor Operation. • Steering and Maneuvering. • Visibility (Including Restrictions Due to Loading.

16. TRAINING REQUIREMENTS (1999 REVISION) TRUCK TOPICS TO BE ADDRESSED: • Fork and Attachment Adaptation. • Fork and Attachment Operation, and Use Limitations. • Vehicle Capacity. • Vehicle Stability. • Operator Vehicle Inspection and Maintenance. • Refueling of the Vehicle. • Charging and Recharging of Batteries. • Vehicle Operating Limitations. • Surface Operating Conditions.

17. TRAINING REQUIREMENTS (1999 REVISION) WORKPLACE-RELATED TOPICS TO BE ADDRESSED: • Composition of Loads to Be Carried • Load Manipulation, Stacking, and Unstacking. • Pedestrian Traffic in Operating Areas. • Restricted Spaces and Operating Locations. • Hazardous (Classified) Operating Locations. • Ramps and Other Sloped Surfaces. • Closed Environments Poorly Ventilated Areas. • Unique or Potentially Hazardous Operating Areas. • The Requirements of the Standard.

18. RETRAINING REQUIREMENTS (1999 REVISION) RETRAINING IS REQUIRED WHEN: • An Unsafe Operation of a Forklift Is Observed. • An Accident or Near-Miss Incident Occurs. • An Operator Receives an Unfavorable Driving Report. • An Operator Is Assigned to a Different Type of Truck. • A Change in Attachment/Handling Equipment Occurs. • Workplace Conditions Changes that Affect Safety. • A Failure Occurs in Written Safety Procedures. • There Is Reason to Doubt Employee Proficiency. • Every Three Years.

19. FORKLIFT SAFETY PROGRAM ELEMENTS OF THE PROGRAM: 1. Written Company Safety Procedures. 2. Employee Training. 3. Measurement of Training Effectiveness. 4. Measurement of Driving Proficiency.

20. FORKLIFT SAFETY PROGRAM WRITTEN COMPANY SAFETY PROCEDURES: 1. Company Forklift Policy Reviewed Annually. 2. Daily Operator Inspections Documented. 3. Driving Training and Proficiency Documented.

21. 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.

22. DEPT - A DEPT - B DEPT - C DEPT - D OFFICE DEPT - E DEPT - F DEPT - G DEPT - H = FORKLIFT ROUTE FORKLIFT TRAFFIC PATTERNS

23. FORKLIFT TYPES AND DESIGNATIONS VARIOUS TYPES OF FORKLIFT CONFIGURATIONS: D Diesel DS Diesel- With Additional Safeguards to Exhaust, Fuel Etc. DY Diesel- Like Ds but Having No Electrical Equipment E Electrically Powered ES Like E but With Additional Spark Precautions Installed EX Like E but With Additional Vapor Precautions Installed G Gasoline GS Gasoline but With Additional Safeguards to Exhaust LP Propane

24. FORKLIFT TYPES AND DESIGNATIONS NOTE: YOU MUST ENSURE THAT THE TYPE OF FORKLIFT YOU ARE USING IS COMPATIBLE WITH THE TYPE OF ENVIRONMENTS AND WORKING CONDITIONS THE VEHICLE WILL BE EXPOSED TO.

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.

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

27. BASIC FORKLIFT PRINCIPLES TYPES OF FORKS • HALF-TAPERED FORKS • - USED WITH HEAVIER LOADS • FULL-TAPERED FORKS • - USED WITH LIGHTER LOADS • - USED WITH NARROW PALLETS

28. CONSULT YOUR VEHICLE OWNERS MANUAL BASIC FORKLIFT PRINCIPLES TYPES OF TIRES AIR • PNEUMATIC AIR FILLED TIRES • - USED WITH HEAVIER LOADS • - OUTDOORS OR UNEVEN SURFACES SOLID RUBBER • PNEUMATIC SOLID TIRES • - PUNCTURE PROOF • - INTERCHANGED WITH AIR FILLED

29. CONSULT YOUR VEHICLE OWNERS MANUAL BASIC FORKLIFT PRINCIPLES TYPES OF TIRES CUSHION • CUSHION TIRES • - INDOORS OR SMOOTH SURFACES SOLID RUBBER • SOLID TIRES • - PUNCTURE PROOF • - SMOOTH INDOOR SURFACES

30. TRAVEL TRAVEL FORKLIFT BASIC FORKLIFT PRINCIPLES AUTO STEERING VERSES FORKLIFT STEERING: AUTO

31. TRAVEL 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. AUTO

32. TRAVEL BASIC FORKLIFT PRINCIPLES AUTO STEERING VERSES FORKLIFT STEERING: 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

33. 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.

34. BASIC FORKLIFT PRINCIPLES OPERATING NEAR PEDESTRIANS • Three mph Speed Limit Near Pedestrians. • Establish Eye Contact When Possible. • Acknowledge Their Presence With A Nod. • Avoid Congested Pedestrian Areas If Possible. • Panic Stop Distances For Typical Loaded Truck. • - 01 mph = 1 - 3 Feet • - 10 mph = 22 Feet • - 18 mph = 55 Feet

35. COUNTER WEIGHT PIVOT POINT PIVOT POINT COUNTER WEIGHT CONSULT YOUR VEHICLE OWNERS MANUAL BASIC FORKLIFT PRINCIPLES LIFTING PRINCIPLE

36. REAL HEAVY PARTS 6500lbs CONSULT YOUR VEHICLE OWNERS MANUAL BASIC FORKLIFT PRINCIPLES LIFTING PRINCIPLE MOVING THE LOAD AWAY FROM THE BACKREST CAN LOWER THE RATED CAPACITY OF THE FORKLIFT BY HUNDREDS OF POUNDS! INCORRECT

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

38. REAL HEAVY PARTS 6500lbs BASIC FORKLIFT PRINCIPLES CENTRIFUGAL FORCES 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!

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

40. 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 FORKLIFT OPERATING PRINCIPLES PRE-USE INSPECTION

41. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES TYPES OF POWER SOURCES • BATTERY POWERED • PROPANE POWERED • DIESEL POWERED • GASOLINE POWERED

42. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES INSPECTION OF POWER SOURCES • BATTERY POWERED • - REQUIRES CONSTANT CHARGING • - NO IGNITION SOURCES IN CHARGING AREA • - FOLLOW LOCAL CHARGING PROCEDURES

43. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES 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.

44. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES BATTERY SAFETY PRECAUTIONS 8. Battery Cover Must Be Left Open During Charging. 9. Ventilation Ensures Clean Air and Heat Dissipation. 10. Always Disconnect Charging Connector Properly. 11. Only Pull on Charging Connector in an Emergency. 12. Properly Reposition Battery After Removal. 13. Improperly Positioned Batteries May Shift. 14. Use Wooden (or Approved) Spacers As Necessary.

45. DISTILLED WATER BATTERY FORKLIFT OPERATING PRINCIPLES BATTERY FILLING PRECAUTIONS OK!

46. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES HANDLING BULK ELECTROLYTE 1. Bulk Containers Must Be Moved Using Carboy or Tilter. 2. Siphons Are Acceptable. Never Start Siphon By Mouth. 3. Never Smoke Around Electrolyte. 4. Eliminate Sparks or Other Ignition Source In Charging Area. 5. Use Only Non Sparking, Non Conductive Tools. 6. Apply Vehicle Emergency Brake When Charging. 7. Inspect Vent Caps On Battery. Ensure They Are Free.

47. WATER ACID CORROSIVE FORKLIFT OPERATING PRINCIPLES ELECTROLYTE MIXING PRECAUTIONS NO!

48. ACID CORROSIVE WATER FORKLIFT OPERATING PRINCIPLES ELECTROLYTE MIXING PRECAUTIONS YES!

49. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES INSPECTION OF POWER SOURCES • PROPANE POWER • - INSPECT TANK FOR SERVICEABILITY • - INSPECT PROPANE TRANSFER SYSTEM • - INSPECT TANK RESTRAINT SYSTEM • - FOLLOW LOCAL REPLACEMENT PROCEDURES

50. CONSULT YOUR VEHICLE OWNERS MANUAL FORKLIFT OPERATING PRINCIPLES 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.