Forklift Safety & Certification Training Course

1. Forklift Safety & Certification Training Course Trainer: <insert name here>

2. Why is ‘Safety’ so important? • OSHA estimates forklifts cause roughly 85 fatal accidents per year. • 34,900 accidents result in serious injury. • 61,800 accidents are classified as non-serious. • According to the Industrial Truck Association, there are about 855,900 forklifts operating in the U.S. therefore, over 11% of all forklifts will be involved in some type of accident each year (assuming only one accident per forklift.) • 42.5% of fatalities occur in a fabrication setting. • 12.5% of fatalities occur in a wholesale trade setting.

3. Fatal Forklift Accident Causes.. • Crushed by vehicle tipping over 42% • Crushed between vehicle and a surface 25% • Crushed between two vehicles 11% • Struck or run over by a forklift 10% • Struck by falling material 8% • Fall from platform on the forks 4%

4. Preventing These Accidents • Studies show that many of these accidents could have been prevented by better training. • As OSHA and Ferguson Enterprises requires, drivers must be properly trained to do so. • The lesson learned is, operating a forklift without training is dangerous and can even be fatal to you or other associates working in the area.

5. Why We Train Continues… • Training can also prevent or reduce the severity of an accident related to the stability of a lift truck traveling with an elevated load. • Even if drivers ignore this rule, and the vehicle tips over, injuries are usually minor if they stay with the vehicle instead of jumping off.

6. Ten Lift Truck Accidents A Professional Driver Should Know How to Avoid.. • Co-Workers Hit by a lift truck. • Co-Workers Hit by a load. • Driver Hit by a Falling Object. • Co-Workers Hit by a Falling Object. • Hit by Mast. • Getting On or Off a Truck. • Collisions with Other Trucks or Vehicles. • Falling Off Loading Docks. • Hit by Objects While Driving. • Tip-Overs.

7. Your Participation… Is Highly Encouraged. If you can share actual forklift incidents that have occurred to help with impact of the training’s importance.

8. ‘Pre-Test Exercise’ All questions are all ‘True’ or ‘False’ A total of 16 questions…

9. Ferguson Forklift Safety Video (15 min)

10. Forklift Engineering Principles Load Center Maximum Lift Capacity Stability Triangle Fulcrum Point

11. Forklift Engineering Principles • To understand the ‘Load Center’ and ‘Maximum Lift Capacity’ you need to find the lift’s ‘Data Plate’. • Information on the ‘Data Plate’ includes make, model, weight, maximum capacity and load center.

12. Forklift Engineering Principles continued… • Most forklifts are designed with a 24” load center. • A standard pallet is 48” x 48”; half of this measurement is your 24” load center. • The load center is determined by measuring from the heel of the forks out to the tips. • For example: It may state that at 24” load center you can safely pick up 5000 lbs. to the full extension of the mast, however, at a 36” load center you can only safely pick up 4000 lbs. at full extension. • For complete safety, make sure you check the capacity rating on your lift’s data plate.

13. What is the ‘Stability Triangle’? • This is an imaginary triangle. • The base of this triangle is the front wheel axle, which supports the bulk of the load. • The top of the triangle is the rear pivot pin on four-wheeled vehicles or the rear wheel on three-wheeled vehicles.

14. Stability Triangle

16. Fulcrum Point • The front wheels of a lift serve as the Fulcrum Point between the weight of the truck and the weight of the load being carried. • If the weight of the load is equal to the weight of the truck, with equal distances between the centers of gravity, it is possible to ‘seesaw’ a lift truck on its front wheels.

17. If we rearrange the load so that the load’s center of gravity is farther away from the fulcrum point, this will cause the Center of Gravity for both the truck and the load to shift beyond the front wheels of the truck, the truck will tip forward.

18. If, on the other hand, we arrange the load so that the load’s center of gravity is closer to the fulcrum point, this will cause the center of gravity for both the truck and the load to shift behind the front wheels of the truck. With this arrangement there is no danger of the truck tipping forward.

19. Pre-Operation Classes/Types of Forklifts Comparing Forklifts to Automobiles Pre-Shift Inspections

20. Classifications of Forklifts: • Class 1 – Electric motor, sit down rider, counter-balanced trucks (solid or pneumatic tires) • Class 2 – Electric motor, narrow aisle trucks (solid tires) • Class 3 – Electric motor hand trucks or hand/rider trucks (solid tires) • Class 4 – Internal combustion engine trucks (solid tire) • Class 5 – Internal combustion engine trucks (solid/pneumatic tires) • Class 6 – Electric and internal combustion engine tractors (solid/pneumatic tires) • Class 7 – Rough terrain trucks (pneumatic tires)

21. Types of Forklifts: • Type D - Diesel powered • Type E - Electric powered • Type G - Gasoline powered • Type LP - Propane gas powered

22. Comparing Forklifts to Automobiles • Driving a forklift is different than driving a car.. • A forklift is much heavier than a car. • Average car weighs 3000 lbs. • Average forklift weighs 9,000 lbs. • A forklift is easier to tip over on a turn whether it is loaded or not. • A forklift is not as responsive as a car as it is turned by moving the rear wheels. • A forklift can be driven backwards or forwards equally well.

23. Pre-Shift Inspection • Prior to each shift, the operator must conduct a documented inspection of the lift to ensure that it is in proper working order.

24. Operator’s Daily Checklist(Page 1)

25. Operator’s Daily Checklist (page 2)

26. The following items must be checked prior to each shift for damage and proper operation. • Overhead guard • Seat & Seat belt • Fuel System • Tires • Hydraulic System • Mast • Lift Chains/Carriage • Forks

27. Remember… • If a deficiency is found DO NOT operate the lift. The forklift must be put out of service (OOS) until repairs are made. • Notify your supervisor if problems are discovered so that the lift can be repaired as soon as possible. DO NOT ATTEMPT TO FIX ANY PROBLEM YOURSELF!

28. General Operation Before Turning the Key In the Driver’s Seat

29. Before Turning the Key… • Before turning the key The proper way to mount and dismount a forklift is to face the unit and use three points of contact; under NO circumstances should an associate jump onto or off of a forklift. • The seatbelt must be worn at all times. No exceptions.

30. Before Turning the Key… • Operators should be familiar with the controls of the equipment they are operating prior to turning the key and know that not all forklifts have the same control placement. • Each associate should take the time to familiarize themselves with the warning labels associated with each piece of equipment they will be using.

31. In the Driver’s Seat • A powered industrial truck must always be started from the drivers’ seat, never energize a forklift without an operator. • Before moving the forklift, the operator should take note of any workplace hazards including but not limited to rough or uneven surfaces, unusual sized loads, wet areas, narrow aisles, and pedestrians.

32. In the Driver’s Seat • Once the motor is started the operator should carry the forks approximately 2 – 4 inches off the floor. • Only one associate is allowed on a forklift at a time, NEVER allow any one to “piggy back” or ride on a forklift. • Associates are NOT to be lifted on a pallet to retrieve materials from the racks.

33. In the Driver’s Seat • Powered Industrial trucks are heavy and will not stop quickly; therefore the weight of a load must be taken into consideration when attempting to stop. • Ramps, inclines and uneven terrain (such as outdoors) can pose special challenges to a forklift operator. • Changes in ground surface may require an operator to alter their intended route and travel at a slower speed.

34. In the Driver’s Seat • Loaded forklifts should always be driven with a load “uphill”, which translates into driving up and backing down the incline. • When operating a forklift that is not loaded always drive with the forks “downhill”, this translates into backing up a ramp and driving down it.

35. Load Handling Lifting a Load Traveling with a Load Placing a Load

36. Load Handling - Lifting a Load • Make sure the load does not exceed the capacity of the forklift • Be sure to center the forks and evenly distribute the weight • Made sure the load is balanced and secure • Check for obstructions overhead • Drop the forks to the floor • Drive as far into the load as possible • Tilt the load back slightly and lift • Back out slowly, clearing racks and obstacles • Lower the load to a safe traveling height • Always completely stop before raising or lowering the load

37. Load Handling – Traveling with a Load • Pedestrians always have the right-of-way • When traveling always keep the load tilted back slightly • Keep the forks at a safe height • Before moving always check behind and around the unit for other hazards • Travel in reverse only if the load is so large that it obstructs the operator’s view • Drive at a safe speed • Sound the horn when approaching aisles and corners • Avoid sudden braking

38. Load Handling – Placing a Load • Stop the PIT directly in front of the desired location • Slowly raise the load to the required height • Move forward slowly with the raised load • Position the load for placement, tilting it forward for placement • Place the load straight, once it is settled, back up slowly • Make sure the forks clear the pallet before turning or changing the height • Check behind and on both sides of the PIT before backing

39. Load Handling – Placing a Load • Never let any associate stand or walk under a raised load. • Make sure operators are aware of any special requirements an unusually shaped load may have before picking it up.

40. Load Handling – Placing a Load • Ferguson operators are constantly removing material from and loading material onto delivery trucks, this can result in some very common injuries, and even in deaths. • Before entering a truck or trailer the PIT operator must make sure that the vehicle has been secured. • Operators should not drive into a trailer or truck unless authorized to do so; communication with the driver is amust.

41. Miscellaneous Fueling Corrective Action What’s Wrong?

42. Remember… • Never come into contact with fuels or battery acids of your forklift or picker. • Always wear personal protective equipment.

43. Fueling • Operators must always wear the appropriate PPE when changing tanks (Gloves). Propane can cause “freeze” burning if it comes into contact with the skin; operators should handle all tanks very carefully. • Tanks are never to be changed near open flames or heat sources this means NO SMOKING.

44. Fueling • Close the fuel line valve but keep the engine running – this will prevent any propane from being left in the fuel line. • Shut off the ignition after the engine stops. • Check the condition of all valves and seals before connecting a new tank.

45. Fueling • Most propane is odorized so an associate will be able to smell a leak. In the case of a leak propane will settle to the floor, as it is heavier than air. If a leak is detected the PIT must be removed from use and place Out of Service until it is repaired. All propane tanks are to be stored outside the building to prevent any leaking gas from accumulating. • Propane powered forklifts give off Carbon Monoxide – a colorless, odorless, flammable and toxic gas. CO will reduce the blood’s ability to carry oxygen and is therefore very dangerous when in large quantities.  

46. Corrective Action • Once certified, it is the responsibility of each associate to operate the equipment as discussed in this training program. • Any associate found to be operating in an unsafe manner is subject to retraining and disciplinary action…

47. Disciplinary measures for violation of safety policies… • First Offense • Written warning and mandatory retraining. • Second Offense • 3 to 5 Day suspension without pay and mandatory retraining. • Third Offense • Termination

48. What’s Wrong? Study the picture to the right. Can you identify what is wrong with this situation?

49. What’s Wrong? • Study the picture to the right. • Can you identify what is wrong with this situation? • Assume the forklift is moving forward.

50. What’s Wrong? Study the picture to the right. Can you identify what is wrong with this situation?