1. Powered Industrial Truck (Forklift) Refresher Course
Outline
Responsibilities
Definitions
Classes of Powered Industrial Trucks
Components of a Powered Industrial Truck
Inspection

2. Outline continued
Fueling/Charging
Proper Operation
Review

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

4. Responsibilities

5. Responsibilities The employer must: Communicate hazards to employees.
Comply with State and Federal Safety Rules and Regulations.

6. 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.

7. Definitions

8. 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.

9. 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.

10. 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.

11. 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.

12. Classes of Powered Industrial Trucks

13. 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

14. Components of a Powered
Industrial Truck

15. Components of a Powered Industrial Truck

16. Controls and Instruments
Fuel Gauge
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 Gauge
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 Gauge
Indentifies the battery strength of the piece of equipment.

17. Controls and Instruments

18. Controls and Instruments
Oil Pressure Gauge
Indentifies the engine oil pressure
Engine Hour Meter
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 Mirror
The mirror attached to the powered industrial truck that gives a visual representation of the area behind the driver

19. Safety Features Seat Belt
Keeps you secured to the truck in the event of an accident
Overhead Guard
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.

20. Safety Features A horn must be used to notify others when:
Driving around a corner
Visual obstruction is present
Poor lighting conditions
Lowering your load

21. Inspection

22. Inspection Before and after each use you are responsible for checking:
The overhead guard for any broken welds, missing bolts, or damaged areas
Hydraulic cylinders and lines. Make sure they are free from leaks and lines are in good condition showing no signs of cracking
The mast assembly for broken welds, cracks or bends
All lift chains and rollers for excessive wear, damage, kinks, rusting, need for lubrication, squeaks and bends

23. Inspection Before and after each use you are responsible for checking:
Forks and carriage. Make sure that there are no cracks or bends in the metal. Make sure attachments being used are securely fastened
Steering mechanism for excessive motion
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
Lights and horn to make sure they are functioning properly
The battery to make sure all caps are in place and that the cables are free from damage

24. Inspection After completing the visual inspection, if any problems are
found:
Tag the equipment identifying that it is not to be used
Report the problem to your supervisor

25. Fueling/Charging

26. Types of Fuels
Propane Gasoline
Battery Diesel

27. Diesel or Gasoline fueling
To properly refuel a powered industrial truck the following
steps should be taken:
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
Smoking is prohibited when refueling or operating a powered industrial truck and signs must be posted to that effect
Proper PPE must be worn

28. Proper Refueling
Safely refueling a propane cylinder requires the following
steps:
Turn the gas valve to the off position and let the engine run until it stalls
Turn off the ignition and the lights and set the emergency brake
Check the connections for damage
Remove empty tank and store it or secure the tank in a vehicle and bring it to the service station to be filled
Install the new or filled tank securely
Check the connection for leaks and damage
Proper PPE must be worn

29. 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.

31. Proper Operation

32. Transporting and Maneuvering
When maneuvering and transporting:
Give pedestrians the right of way
Activate strobe lights and utilize the horn when going around corners
Always pay attention to the path of travel
Never lift loads when the powered industrial truck is moving
Approach any potential obstacle slowly and with caution

33. Transporting and Manuveuring
When loading and unloading a trailer you should:
Inspect the floor of the trailer
Chock the wheels of the trailer
Make sure dock plates, boards and ramps are in place and secure

34. Transporting and Maneuvering
When maneuvering and transporting:
Ensure that the loads are neatly stacked, stable, evenly distributed
Space the forks under the load as far as possible. This will ensure that the load is evenly distributed.
Approach the load with caution with the mast in a vertical position.
Lift the forks only as high as needed to move the load 6 to 8 inches.
Tilt the forks back for added stability

35. Transporting and Maneuvering
If the powered industrial truck is not loaded, drive in reverse up the incline. Drive forward down the incline.
If the powered industrial truck is carrying a load Drive forward up the incline. Drive in reverse down the incline.

36. 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.
Always cross railway tracks on a diagonal
Park forklift at least 8 feet away from railway tracks
Obey any warning signs or alert systems

37. Review

38. Review The following are key points to remember as an authorized
operator:
Operate only the equipment that you are authorized to use.
Familiarize yourself with the piece of equipment that you are going use and follow all of its operating procedures
Inspect equipment thoroughly prior to use
Know your travel routes and overhead clearance levels
Do not allow any passengers
Stay within the safety cage of the powered industrial truck at all times.
No matter how short or long distance always fasten your seat belt.