Forklift Operator Training 29 CFR 1910.178

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Forklift Operator Training29 CFR 1910.178
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Is Forklift Training Necessary?

• About 100 deaths each year
• About 95,000 accidents each year
• Bankruptcy
• New OSHA training standard

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Forklift Operating Goals

• Hazards and forklift stability
• Inspecting and operating a forklift
• Quiz

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Authorized Operator

• Only trained and authorized personnel are
  permitted to operate a forklift
• Keep unauthorized employees off of forklifts
• Keep pedestrians away from the operating zone of
  a forklift
• Lock out unsafe lifts as determined in a
  preoperation inspection

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Operating Hazards

• Workplace hazards ramps, railroad tracks,
  slippery floors, poor lighting, congestion
• Loads large or bulky, uneven weight, broken
  pallets, poorly stacked
• Pedestrians horseplay, unaware of forklift
  areas, not paying attention

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Nameplate

• OSHA requires a legible nameplate
• Includes modifications attachments
• Capacity
• Load center

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Center of Gravity

• Balance point

• Distance from the edge of the item to the items
  center of gravity

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Load Center

• Distance from vertical face of the forks to the
  loads center of gravity
• A Load center 24"
• B Load center 40"

• 1 inch 100 lbs
• Important reason for keeping the load resting
  against the vertical face of forks

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Stability Triangle

• 3-point suspension

• Forklifts center of gravity

• Combined center of gravity

• Load center beyond 24"

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Combined Actions

• Center of gravity moves side to side

• Center of gravity moves forward

• Center of gravity moves backward to the thin
  portion of the triangle

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Attachments

• Specific operator training
• Weight of attachments
• Increased load center

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Tipping Over

• Do not jump
• Hold onto the steering wheel
• Brace your feet
• Lean away from the fall

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Forklift Operating Goals

• Hazards and forklift stability
• Inspecting and operating a forklift
• Quiz

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Preoperation Inspection

• As an authorized operator, it is your
  responsibility to make sure your forklift
  functions properly
• OSHA requires preoperation inspections
• Company wants to comply with OSHA and be sure
  equipment is maintained

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Walk Around

• Forklift properly disengaged
• Forks down, key off, neutral gear, parking brake
  on
• Left/right side
• Tire condition, tight lug nuts, no debris around
  axle, overhead guard is solid, no debris behind
  the mast
• Front
• Forks in good shape, fork pins in place, backrest
  solid, mast chains greased, hoses in good shape
• Rear
• Counterbalance bolt is tight, radiator clear of
  debris

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In the Seat

• Nonmoving checks
• Gauges, lights, horn, back-up alarm, blinking
  warning light, operate the tilt lift mechanism,
  check the parking brake
• Moving checks
• Put on the seat belt, check the running brakes,
  check the steering
• Look for oil or water leaks on the floor

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Operating a Lift Truck

• Only trained, authorized operators
• Immediately report forklift-related accidents
• Seat belts must always be worn
• No person should stand under elevated portion of
  lift truck
• Forklift controls operated only from drivers
  seat
• Never block exits or emergency equipment
• Smoking is not permitted

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Loading/Unloading

• Before raising a load, understand
• Approximate weight of the load
• Location of the loads center of gravity
• Inspect load for stability, projections, damaged
  pallets before lifting
• Restack unstable loads
• Never place weight on the back of a lift truck
  to increase its capacity
• Towing always done from rear towing pin

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Traveling

• Always look in the direction of travel
• Keep body inside the cage
• When moving, the mast must not be raised
• Sound the horn
• Operate at safe speeds
• When turning, watch rear end swing
• Clearance under overhead installations

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Traveling (cont.)

• Avoid loose objects or holes
• If load blocks view, travel in reverse
• Never carry passengers
• Pedestrians always have the right-of-way
• Safe distance from edge of ramps or docks
• Never eat or drink
• No stunt driving or horseplay

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Ramps and Railroads

• Never turn on a ramp
• On ramps the load should be upgrade
• Ascend or descend ramps slowly
• Railroad tracks are crossed diagonally
• Never park within 8 feet of the center of
  railroad tracks

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Docks

• Inspect the dock plate
• Check the trailer floor condition
• Trailer wheels are chocked
• Nose of the trailer is supported by the tractor
  or a fixed jack

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Parking

• Lower the forks
• Set gear to neutral
• Set the parking brake
• Turn off the key

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Propane Refueling

• Propane is a combustible, compressed gas
• Propane leaks are detected by
• Distinct odor
• Hissing sound
• Frost on fittings
• PPE gloves, safety glasses

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Battery Charging

• Inspect battery connectors for damage
• No smoking in battery-charging area
• Immediately clean up electrolyte spills
• PPE includes face mask, acid-resistant gloves,
  and an apron

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Forklift Operating Goals

• Hazards and Forklift Stability
• Inspecting and Operating a Forklift
• Quiz

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Summary

• Facility hazards
• Load center and capacity
• Preoperation inspection
• Rules of the road
• Refueling

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Quiz

• 1. If your forklift has a rearview mirror,
  looking behind you is not necessary. True or
  False
• 2. Name two of the three ways to detect a
  propane leak _______________, _______________
• 3. Describe the four items that must be completed
  prior to driving your forklift into a trailer.
• 4. If a load blocks your vision, it is OK to
  raise the load while moving to see under it.
  True or False
• 5. Preoperation inspections are done only
  because OSHA says we have to do them. True or
  False

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Quiz (cont.)

• 6. Attachments reduce capacity by increasing the
  load center and adding weight. True or False
• 7. Minimum PPE items required when refueling a
  propane tank are ___________, ____________.
• 8. The most important differences between a
  forklift and a car are weight and steering. True
  or False
• 9. Name at least one condition that when
  combined with turning sharply may cause a
  tipover.
• 10. Pedestrians have the right-of-way only while
  in designated pedestrian lanes. True or
  False

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Quiz Answers

• 1. False. You must always look behind you before
  backing up.
• 2. Hissing sound, distinct odor, or frost on
  fittings.
• 3. Chock the wheels, support the nose of the
  trailer, inspect the dock plate, check the
  trailer floor.
• 4. False. Never drive with the load up. Drive in
  reverse when the load obstructs forward vision.
• 5. False. Inspections are also done so that the
  operator can prevent mechanical failure accidents
  and because the company needs to prove compliance
  with OSHAs requirement.

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Quiz Answers (cont.)

• 6. True. Attachments are heavy, and they cause
  the load center to move away from the forklift.
• 7. Gloves and safety glasses are the minimum PPE
  required.
• 8. True. There are many differences, but the
  most significant are weight and steering.
• 9. Hitting a pothole, carrying an off-center
  load, getting a flat tire, having a raised
  tilted back load, or being on a ramp.
• 10. False. Pedestrians always have the right of
  way.