Powered Industrial Truck (Forklift) Refresher Course

Outline• Responsibilities• Definitions• Classes of Powered Industrial Trucks• Components of a Powered Industrial

Truck• Inspection

Outline continued

Fueling/Charging Proper OperationReview

Introduction

This is a refresher course for the OSHA 1910.178 Powered Industrial Truck standard.

Responsibilities

Responsibilities

The employer must: • Communicate hazards to employees. • Comply with State and Federal Safety

Rules and Regulations.

Responsibilities As an operator of a powered industrial truck, you have several responsibilities:

• Perform a daily inspection of the machine and document the condition of the equipment

• Safely operate the piece of equipment that you have been assigned to use

• Report any items that are in need of repair to your supervisor and do not operate the machine until the items have been corrected.

Definitions

Definitions The most common powered industrial truck is the sit down rider type, but there are many different pieces of equipment that are classified as powered industrial trucks and are subject to the powered industrial truck standard. This may range from a motorized hand truck (class III) to a Bobcat type machine with a fork attachment.

Definitions Center of Gravity – The point at which the load of the powered industrial truck is concentrated.

If the center of gravity remains inside the triangle, the truck will not tip over.

Load Capacity Each powered industrial truck should have a name

plate secured to it. The name plate will give the load

capacity of the truck.

Do not exceed the rated load capacity.

Exceeding the load capacity may cause the truck to

tip causing harm to you and bystanders.

Attachments

Powered industrial trucks serve a variety of purposes

and there are many different attachments that may be

added on and used safely. Each attachment requires

training specific to that piece of equipment.

Attachments may require specific operating

conditions and/or PPE

Only use attachments that are designed for that specific

powered industrial truck.

Classes of Powered Industrial

Trucks

Seven Classes of Powered Industrial Trucks

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

Components of a Powered

Industrial Truck

Components of a Powered Industrial Truck

Controls and Instruments

Fuel Gaugeo Identifies how much fuel is

currently on board the piece of equipment. The fuel gauge reading must be taken during the daily checks

Engine Temperature Gaugeo Indentifies the running

temperature of the engine on the piece of equipment. The C on the gauge refers to the engine being cold and H refers to the engine being hot

Ampere Gaugeo Indentifies the battery strength

of the piece of equipment.

Controls and Instruments

Controls and Instruments

Oil Pressure Gaugeo Indentifies the engine oil pressure

Engine Hour Meter o This meter records the total amount of

hours that the engine has been used. This reading must be recorded on the daily inspection forms because it is used to schedule maintenance on the piece of equipment

Rear View Mirroro The mirror attached to the powered

industrial truck that gives a visual representation of the area behind the driver

Safety Features

Seat Belto Keeps you secured to the

truck in the event of an accident

Overhead Guard o Prevents the powered

industrial truck from crushing you in the event of a tip-over, but this guard is only effective with the combined use of a seatbelt.

Safety Features

A horn must be used to notify others when:o Driving around a

cornero Visual obstruction is

present o Poor lighting

conditions o Lowering your load

Inspection

Inspection

Before and after each use you are responsible for checking: o The overhead guard for any broken welds, missing bolts, or

damaged areaso Hydraulic cylinders and lines. Make sure they are free from leaks

and lines are in good condition showing no signs of cracking o The mast assembly for broken welds, cracks or bendso All lift chains and rollers for excessive wear, damage, kinks,

rusting, need for lubrication, squeaks and bends

Inspection

Before and after each use you are responsible for checking: o Forks and carriage. Make sure that there are no cracks or bends in

the metal. Make sure attachments being used are securely fastened o Steering mechanism for excessive motion o Brakes for proper function. If the pedal goes all the way to the

floor when you apply the brake, that is an indication that the breaking system is not functioning properly. Make sure the emergency brake works. There should be no movement of the powered industrial truck when an emergency brake is engaged

o Lights and horn to make sure they are functioning properly o The battery to make sure all caps are in place and that the cables

are free from damage

Inspection

After completing the visual inspection, if any problems are

found:o Tag the equipment identifying that it is not to be used o Report the problem to your supervisor

Fueling/Charging

Types of Fuels

Propane Gasoline

Battery Diesel

Diesel or Gasoline fueling

To properly refuel a powered industrial truck the following

steps should be taken:o All internal combustion engines must be turned off

before refueling. Refueling should be in the open or in specifically designated areas, where adequate ventilation is provided

o Smoking is prohibited when refueling or operating a powered industrial truck and signs must be posted to that effect

o Proper PPE must be worn

Proper Refueling

Safely refueling a propane cylinder requires the following

steps:o Turn the gas valve to the off position and let the engine

run until it stallso Turn off the ignition and the lights and set the

emergency brakeo Check the connections for damageo Remove empty tank and store it or secure the tank in a

vehicle and bring it to the service station to be filledo Install the new or filled tank securelyo Check the connection for leaks and damageo Proper PPE must be worn

Charging

Battery-charging installations must be located in areas

designated for that purpose. They must be capable of flushing

and neutralizing spilled electrolyte. The charging apparatus

needs to be protected from damage by trucks, adequate

ventilation for dispersal of gases or vapors from gassing

batteries.

Proper Operation

Transporting and Maneuvering

When maneuvering and transporting: o Give pedestrians the right of wayo Activate strobe lights and utilize the horn when going around

cornerso Always pay attention to the path of travel o Never lift loads when the powered industrial truck is moving o Approach any potential obstacle slowly and with caution

Transporting and ManuveuringWhen loading and unloading a trailer you should:

o Inspect the floor of the trailero Chock the wheels of the trailer o Make sure dock plates, boards and ramps are in place

and secure

Transporting and Maneuvering

When maneuvering and transporting: o Ensure that the loads are neatly

stacked, stable, evenly distributedo Space the forks under the load as

far as possible. This will ensure that the load is evenly distributed.

o Approach the load with caution with the mast in a vertical position.

o Lift the forks only as high as needed to move the load 6 to 8 inches.

o Tilt the forks back for added stability

Transporting and Maneuvering

o If the powered industrial truck is not loaded, drive in reverse up the incline. Drive forward down the incline.

o If the powered industrial truck is carrying a load Drive forward up the incline. Drive in reverse down the incline.

Crossing Railway Tracks

There are many areas where employees may need to cross

railway tracks. This poses a unique hazard and caution must

be exercised.

o Always cross railway tracks on a diagonal

o Park forklift at least 8 feet away from railway tracks

o Obey any warning signs or alert systems

Review

Review

The following are key points to remember as an authorized

operator: o Operate only the equipment that you are authorized to use.o Familiarize yourself with the piece of equipment that you are

going use and follow all of its operating procedureso Inspect equipment thoroughly prior to useo Know your travel routes and overhead clearance levels o Do not allow any passengers o Stay within the safety cage of the powered industrial truck at all

times. o No matter how short or long distance always fasten your seat belt.