Alabama Homebuilders Self Insurers Fund - Forklift Operator Training Program Presented by the AHBSIF Loss Control Department

Alabama Homebuilders Self
      Insurers Fund

   Forklift Operator Training Program

Presented by the AHBSIF Loss Control Department

Contents
I.     Course Outline
II.    Forklift Basics
III.   Power Sources
IV.    Emergency Situations
V.     Operation Safety
VI.    Driving Test

I. Course Outline
This presentation provides the following:
  • The importance of forklift safety
  • Forklift component, weight, stability, and
    operation at speed
  • Safe handling of power sources i.e. fuels and
    batteries
  • Daily maintenance and safety check
    procedures

Benefits of Operator Training

 Improved safety for the operator and others
 The operator learns how to perform a pre-shift inspection
   • Reduces down time and maintenance costs
   • Increases productivity
 The equipment is in better condition
   • Employees understand the value of the equipment and how to
     use it efficiently
 Operator training and progress is documented
 OSHA requirements are fulfilled

II. Forklift Basics

Section II will cover:
  •   Forklift Types
  •   Forklift Components
  •   Vehicle Dynamics
  •   Understanding Signage

Forklift Types
All Terrain        Sit-Down Rider
                  (Pneumatic Tire)

Components of a Sit-Down Rider
                                           Upright
                    Overhead Guard
 Operator
 Restraint System                                    Lift Cylinder

 Fuel Tank
                                                              Backrest

Counterweight
                                                            Tilt Cylinder

                                                              Carriage
  Steering Axle
  and Wheels              Drive Axle and
                          Wheels

Components of an All Terrain
                                   Lift Cylinder
    Telescoping Boom
                                       Overhead Guard
   Backrest

Tilt Cylinder          Carriage                    Operator
                                                   Restraint
                                                   System

   Outriggers

                                  Steer Axles
                                  and Wheels

Data Plate
   • The data plate must be
     in legible condition
   • A data plate provides
     the following
     information
     – Attachment capacities
     – Maximum weight capacities
     – Maximum lift height
        • (all machines will post this)

Forklift Weight
• Listed capacities do not indicate the machines
  total weight
• A forklift can weigh two to three times as much
  as the lifted capacity
• A forklift usually weighs twice its capacity
                       2:1 ratio

         Component              Estimated lbs
         Truck Weight              8,000 lbs

           Capacity                4,000 lbs

          Operator                 175 lbs

            Total                 12,175 lbs

Load Center
 The load center rating of a forklift is the
  maximum distance from the face of the forks to
  the center of gravity of a load.

 The data plate will have this information.

 Standard forks measure 24” at the load center.

 For every inch beyond the rated load center that
  the load is placed, approximately 100 lbs. of
  capacity is lost.

Load Center

        24”

Stability

Even though a forklift has four wheels, it is
 only supported at three points.

The steering axle of most four-wheel
 forklifts is attached by means of a pivot
 point in the center of the rear axle.

Center of Gravity
 The black dot in the triangle below represents the Center
  of Gravity.
 The Center of Gravity (CG) shifts according to the
  movements of the truck.
 If the CG moves outside the triangle the forklift can
  overturn.

Center of Gravity
 Figure 1 shows
  the CG shift when
  a loaded machine
  is braking.

 Figure 2 shows
  the CG shift when
  a machine is
  uneven or turning
  with excess
  speed.

Center of Gravity
                           As the CG gets
                Zone        higher, the
                  3
Lift Height

                            stability of the
                            forklift gets
                Zone
                  2
                            smaller.
                           Loads always
                            kept as low as
                Zone
                  1         possible.

              Stability

All Terrain – Special Precautions

                    Telescoping
                     Boom
                    Chassis
                     Leveling
                    Outriggers

All Terrain Lifts
Telescoping boom
  • Operator must consider lift height and
    forward reach
  • Load capacity is affected by boom length
  • Load charts will display capacities for
    specific boom lengths

All Terrain Lifts
Chassis Leveling
  • Frame must be leveled before raising the
    boom or mast with or without a load.
  • Lateral leveling should not be used to
    position an elevated load
  • Lower the load and reposition the all terrain
    lift
  • Outriggers and surface conditions will affect
    load capacities

Sample Load Chart – Outriggers Down

Sample Load Chart – Outriggers Up

All Terrain Lifts
Suspended Loads
  • Never exceed the manufacturer’s lift
    capacity while handling suspended loads.
  • Never drag a load horizontally.
  • Transport with the load as low as possible.
  • Limit speed while loaded during transport.
  • Use tag lines when possible to limit load
    swing.

Signaling
Operators must only respond to
 signals given by the designated signal
 person.
Standard hand signals are to be used
 during load handling (ANSI/ASME
 B30.5)
Signalers and Operators may
 designate their own hand signals if
 they are understood by both parties.

Rigging
 Types of rigging for picking loads may include:
   •   Synthetic slings
   •   Wire rope
   •   Chains
   •   Hooks & Shackles
   •   Slab Clamps
 All rigging equipment must be inspected prior to
  use
 If the equipment is faulty or unfit for service, it
  must be removed and/or replaced

Forklift Safety Equipment

 Roll Over Protection System (ROPS)
   • Overhead Protection
   • Seatbelt
   • Protective cage
 Pedestrian Warning Devices
   • Headlights, Brake Lights
   • Amber Strobes
   • Horn and Back-Up Alarm
 Operator’s Manual
   • Includes safe operating procedures and capacities

Safety Signage
NOTE
   • This message is used when special information,
     instructions, or identification is required relating to
     procedures, equipment, tools, pressures, capacities,
     and other special data.
IMPORTANT
   • This message is used when special precautions
     should be taken to ensure a correct action or to avoid
     damage to, or malfunction of, the truck or a
     component.
CAUTION
   • This message is for proper precautions which, if not
     followed, can result in personal injury.
WARNING
   • This message is used when a hazard exists which can
     result in injury or death if proper precautions are not
     taken.
DANGER
   • This message is used when an extreme hazard exists
     which will result in death or serious injury if proper
     precautions are not taken immediately.

III. Power Sources

 Section III will cover:
  • Liquified Petroleum Gas
  • Compressed Natural gas
  • Gas & Diesel
  • Batteries

Liquefied Petroleum Gas (LPG)
 Must be operated in well ventilated areas.
 Heavier than air and will settle.
 Extremely flammable. Avoid all sources of
  ignition.
 It is compressed under high pressure in the tank.
 LPG in liquid state has a temperature of 44°
  below zero. Can cause frostbite on contact with
  skin.
 Chemicals are added to give the gas an odor
  which helps identify leaks.

LPG Tank Handling & Storage
 An area should be designated for the storage and
  changing of LPG tanks.
 Tanks should always be stored in their upright
  position with gauges and valves at the top whether
  empty or full.
 When forklifts are parked overnight or for extended
  periods the service valve of the tank must be closed.
 Never park a forklift near a source of heat.
 Wear proper safety equipment if needed when
  handling tanks.

LPG Tank Removal
 Wear required PPE.
 Do not smoke.
 Purge the fuel line by closing the tank’s service
  valve and waiting for the engine to run out of
  fuel. (Controls in neutral, forks down, brake on,
  ignition off.)
 Once the service valve is closed, unscrew the
  line connection and move the hose out of the
  way.
 Carefully remove the tank from the mounting
  bracket.

LPG Tank Installation
 Select a replacement tank in good condition.
 Do not roll or drag the new tank to the machine.
  Use a cart or other suitable equipment.
 Position the tank in the mounting bracket by
  aligning the collar hole over the mounting
  bracket pin. (This is important for fuel
  consumption and safety)
 Check all rubber seals in the tank and fuel line
  connection.

LPG Tank Installation
Reconnect the fuel line connection until
 tight.
Slowly turn on the service valve to full and
 slightly backseat.
Make sure both tank clamps are adjusted
 properly and hold the tank firmly.
If no leaks are detected, start the forklift
 and check for normal operation.

Compressed Natural Gas (CNG)
The same natural gas that powers hot
 water heaters and furnaces.
CNG is different than LPG in that it
 remains a gas even under high pressure.
CNG is lighter than air and dissipates
 rapidly when released.
CNG tanks are usually permanently
 mounted to the forklift.

Gasoline and Diesel
 The difference between these two fuels is their
  ignition temperatures.
 Gasoline
  • Extremely flammable
  • Colorless
  • Distinctive odor
 Diesel
  • Has higher ignition point than gas
  • Colorless
  • Slight odor, harder to detect than gas

Gas and Diesel Refueling
Most forklift filler caps are equipped with a
 venting device and a fuel screen.
The screen serves as a fire-retardant
 device by keeping fire out of the fuel tank.
Check when refueling to make sure the
 screen is in place.

Gas and Diesel Refueling
Safe refueling checklist:
  • Refuel in designated areas with good
    ventilation
  • Smoking and open flames are prohibited
  • Shut off the forklift, forks on the ground,
    controls in neutral, and set the parking brake
  • Don’t overfill the tank
  • Clean up any spills
  • Use only clean job ready fuel cans

Batteries
Modern machines use either lead-acid or
 lithium-ion batteries
The most common voltages include 12,
 24, 36, and 48 volts.
Manufacturers recommend recharging
 intervals for both types.

Battery Chargers
 Two types:
  • Single Phase charger has two wires and a ground
    with one transformer and two fuses.
  • Three Phase charger has three wires and a ground in
    the power supply cable. It has three transformers and
    three fuses.
 Always correctly match the charger to the
  voltage and amp hour ratings of the battery.
 Also check the input voltage and cycle. Input
  voltage is most commonly 220, 440, or 480, with
  US Standard 60 cycles.

Battery Charging
 Battery recharging requires a special service area for lead acid.
 Vent caps must be left on during charging.
 If the battery is charged while still in the forklift, the compartment
  must be left open.
 The charger should be turned off before it is connected to the
  battery then turned on to begin the charging cycle.
 Color coded connectors help prevent connecting a battery of the
  wrong voltage to the wrong charger or truck.
 Chargers should be properly set to avoid over or under charging.
 The charger should be turned off before disconnecting from the
  battery.

IV. Emergency Situations
Does the facility or site have an
 evacuation procedure?
Are emergency contact numbers readily
 available?
Do any of your employees/co-workers
 have CPR or First Aid training?
Does the facility or site have a first aid kit?

Handling an Emergency
The three C’s: “Check - Call - Care” helps us
  remember what to do in an emergency.

 Check – check the area for your own safety first,
  then the victim's
 Call – for help, 911 or whom ever is in the
  immediate area that can provide assistance
 Care - administer care to the victim, this may be
  first aid or at least stabilization

V. Operation Safety

       Section V will cover:
         •   General Requirements
         •   Driving Around People
         •   Tip Over
         •   Load Handling

Operation Safety
 Trained Operators Only
  • OSHA requires that only trained operators be allowed
    to operate forklifts
 Poor/Aggressive driving is Prohibited
  • Forklifts are heavy and powerful machines
 Read and Understand Operator Instructions
  • You must read and understand the operator's manual
    for each forklift you operate
 Faulty Equipment and Maintenance
  • If at any time the forklift needs repair or is defective it
    must be removed from service and fixed

Driving Around People
 Operators should not rely on pedestrian warning
  devices and mirrors.
 Sound your horn at intersections and blind
  spots.
 If your view is blocked because of the load,
  travel backwards.
 All men and other machinery have the right of
  way.

Driving Around People
Never attempt to move a load that requires
 someone to steady or position the
 material.
  Restack the load and/or
  Secure the load to a pallet.
Never drive the forklift up to someone in
 front of a fixed object. Avoid potential
 “caught between” exposures.

Upright and Fork Safety
Never allow anyone to walk under raised
 upright whether loaded or empty.
Never allow anyone to stand on the forks
 or climb the upright assembly.
Never allow anyone to reach or to step in
 the areas of the mast, carriage, forks, or
 load.
Never allow anyone to ride on the forklift.

Leaving or Parking the Forklift
OSHA considers a forklift unattended if the
 operator is 25 feet away or out of sight of the
 machine. Use the following tips when leaving
 the machine or parking for extended periods:

 Forks on the ground.
 Controls in neutral.
 Parking brake on.
 Turn off the engine.
  • For LPG/CNG shut off the service valve until the
    forklift stops running.

Leaving or Parking the Forklift
 Never park a forklift in the following places:
   • On a grade or around traffic.
   • On a dock ramp, dock leveler, or in a trailer.
   • Where it blocks emergency or fire-fighting equipment
     or emergency travel routes.
 Chock the wheels if needed.
 Turn off power supply and remove the keys if
  possible.

Personnel Elevators

Forklifts are not
 designed to lift people.
Machines designed for
 this are:
  • Scissor lifts
  • Order Pickers (platform
    lift)
  • Elevated work platforms

Personnel Elevators
OSHA does allow the practice under
 specific conditions (ASME B56.1)
  • Company must obtain written permission
    from the forklift manufacturer to use such a
    device
  • The basket or platform must be designed by
    a professional engineer
  • Occupants must wear a harness and lanyard
  • Operators must always be at the controls

Forklift Tip Over
 In case of a tip-over use the following
  precautions:
  •   Wear your seatbelt.
  •   Never attempt to jump from the lift.
  •   Hold the wheel and brace yourself.
  •   The ROPS will limit the tip over.

Handling Loads
Always balance and secure the load.
Never pick loads that are too heavy.
Always be aware of your clearances.
 Check for overhead obstructions or power
 lines.
Center the load. Forks must be at least
 2/3 the length of the load.

Handling Loads

Handling Loads
When picking up place the forks under the
 load as far as possible.
Tilt the mast back slightly for stabilization.
Keep the load low. The forks should never
 be more than 6 to 8 inches from the
 ground.

Stacking
 Keep the forklift square
 Elevate and proceed in
  slowly to set
 Tilt forward for
  placement.
 Lower the forks to place
  load and reverse out
 Use the same procedure
  in reverse when picking a
  load

Traveling
 Understand your work
  environment
 Familiarize yourself with
  the area/facility.
   • Visibility
   • Travel surface
 Maintain a three forklift
  length distance between
  yourself and any
  machine.
 Always yield the right-of-
  way to all vehicles.

Grades, Ramps, and Inclines
 Travel must be straight up
  and straight down. Never
  turn on ramps, slopes, or
  inclines.
 With a load, travel up or down
  with the load pointing
  upgrade.
 Without a load, travel up or
  down with the forks pointing
  downgrade.
 The load should be tilted back
  and raised only as high as
  necessary to clear the
  surface.

Dock Operations
 Before entering a trailer make certain the wheels are
  chocked.
 Check the trailer jacks. Make sure they are fully
  lowered and secured.
 Inspect the floor of the trailer prior to driving on it.
 Check the dock boards between the trailer and the
  dock. Always travel slowly over dock boards.
 Stay away from the edge of the dock.
 Use lights to improve visibility while working in
  trailers.

Hands-On Section
Pre-operation Inspection
Familiarization with operating controls and
 gauges
Driving exercises
  • Figure 8 Test
  • Reverse Mobility
  • Lifting and Carrying

Pre-Operational Checklist
               Item         Ok   repair                Item           Ok   repair

Forks, Backrest, Carriage                 Leaks under Fork Lift

Mast, Chain, Hydraulic                    Seat and Seat belts
Lines
Tires, Axles                              Horn and/or Backup alarm

Overhead Guard/ROPS                       Lights, Bodywork

Fuel Tank & Connections                   Gauges and Instruments

Fuel Level                                Hydraulic Controls & Lift

Engine Oil Level                          All Brakes

Radiator Water Level                      Steering
(Cold)