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Forklift Training

Forklift Training. Forklift Fatalities by Age Group 1992 -1996. There are about 100 fatalities each year related to forklifts. Source: Bureau of Labor Statistics. Content. What is a Powered Industrial Truck? Basic Engineering Principles Safe Operating Procedures

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Forklift Training

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  1. Forklift Training

  2. Forklift Fatalities by Age Group1992 -1996 There are about 100 fatalities each year related to forklifts Source: Bureau of Labor Statistics

  3. Content • What is a Powered Industrial Truck? • Basic Engineering Principles • Safe Operating Procedures • Training, Evaluation and Certification • Special Session: Lawn mowers

  4. What is a Powered IndustrialTruck? • A mobile, power-propelled truck used to carry, push, pull, lift, or stack materials. • Does not cover vehicles used for earth moving and over-the-road hauling.

  5. Classes of Commonly-Used Powered Industrial Trucks* What Type Do We Use • The Industrial Truck Association has placed powered industrial trucks into 7 classes. 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 * Note that this classification refers to commonly used vehicles and does not include all powered industrial trucks covered by the OSHA standard.

  6. Three types of the most Common Lift Trucks • Class I- Electric Motor Rider Trucks • Class III- Electric Motor Hand or Hand/Rider Trucks • Class IV- Internal Combustion Engine Trucks

  7. Class I - Electric Motor Rider Trucks • Counterbalanced rider type, stand up • Three wheel electric trucks, sit-down • Counterbalanced rider type, cushion tires, sit-down (high and low platform) • Counterbalanced rider, pneumatic tire, sit-down (high and low platform)

  8. Class III - Electric Motor Hand or Hand/Rider Trucks • Low lift platform • Low lift walkie pallet • Reach type outrigger • High lift straddle • High lift counterbalanced • Low lift walkie/rider pallet

  9. Class IV – Internal Combustion Engine Trucks Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires Fork, counterbalanced (cushion/solid tires) Class IV - Internal Combustion Engine Trucks - Cushion (Solid) Tires

  10. Basic Engineering Principles • Center of Gravity • Stability Triangle • Longitudinal Stability • Lateral Stability • Dynamic Stability

  11. Fulcrum Principle • Forklifts operate on the fulcrum principle. On a forklift, the fulcrum is located at the front tires.

  12. Center of Gravity • The center of gravity is where all of the weight is concentrated. Consider the center of gravity of the following: 1) the forklift itself 2) the load or object you are carrying 3) the combined weight of the load and the forklift together

  13. Vehicle Stability • During a tipover: • Stay with vehicle and lean away from direction of fall • Don’t jump downward while truck is tipping • Keep load at lowest practical point

  14. Stability Triangle B A Combined Center of Gravity C • The pivot pin in the rear (A) and the two front tires (B and C) form the stability triangle on a forklift. As long as the combined center of gravity remains within this area, the forklift will not tip over.

  15. Stability Triangle Vehicle Center of Gravity (Unloaded) B A Center of Gravity of Vehicle and Maximum Load (Loaded) C • When the vehicle is loaded, the combined center of gravity (red circle) shifts toward line B-C.

  16. Standard Load Center B • Most forklifts specify the maximum load capacity based on a 24” load center. The load center is measured from the vertical face of the forks to the middle of the load. 24" A C

  17. Longitudinal Stability For example: lifting a load that exceeds the maximum lifting capacity. Longitudinal stability is the forklifts’ resistance to overturning frontward or backward. The forklifts’ axis of rotation is the front tires. For example: tipping backwards while going up an incline.

  18. Lateral Stability Lateral stability is the forklifts’ resistance to overturning onto it’s side. For example: turning a curve too fast or too sharp. For example: an unstable load shifting to the left or right.

  19. Dynamic Stability Dynamic stability refers to the stability of the forklift while moving. The faster you go, the more unstable you become!

  20. What are the potential hazards • Forklifts steer from the rear. • Inclines / Wet surfaces • Loads will affect weight and balance. • Some Forklifts weigh 2-3 times more than a car. • Stability may be a concern. • Pallet truck vsRider Truck • Refueling • Battery Charging • Different types of tires. • Speed • Attachments- Barrel Clamp

  21. Battery Charging- Make sure charging area is well ventilated. No smoking or open flames. Wear proper protective equipment. Turn off cables before connecting. Check water level. Leave vent cap on while charging.

  22. Fueling / Charging of Batteries • Exposes workers to hazardous chemicals • Involves electrical hazards, heat build-up, generation of gas • Be aware of all hazards involving fueling • and battery handling

  23. Refueling / Recharging • Turn off the forklift before fueling/ recharging. • No smoking or open flames in the area • Wear gloves for battery refueling • Wear eye protection & shield for splash hazards. • Have a fire extinguisher nearby

  24. Types of Tires • Solid tires • for asphalt and concrete surfaces • Pneumatic tires • for gravel roads or all-terrain What type of tires does your forklift have?

  25. Workplace Hazards • Pedestrians may not be aware of how a forklift handles – braking, rear end swing –Give them the right of way.

  26. Workplace Hazards • Surface conditions: Pot holes, false floors, weight limits, and wet floors can all affect your stability and/or braking distance.

  27. Workplace Hazards • What are you hauling? • If there is a spill, is it safe for you to clean it up, or should the building be evacuated? • Refer to the Material Safety Data Sheet prior to hauling the material.

  28. Loading Dock • Avoid driving too close to the edges of loading docks. • Trailer wheels must be chocked and truck brakes applied. • Dock plates: • Know the capacity. • Good condition? • Properly placed? • Secured? Dock Plate

  29. Safe Operating Procedures Speeding is the number 1 violation regarding forklifts Forklifts and speed – 3 mph, or about walking pace, is expected

  30. Safe Operating Procedures • Cross bumps at an angle - slowly! • Travel with load at low safe level-visibility • Look in the direction you’re traveling • Sound horn at blind corners to warn others

  31. Safe Operating Procedures • Riders are not allowed! • Wear your seat belt! • It will keep you within the forklifts’ rollover protection system

  32. Safe Operating Procedures Parking: • Lower forks to ground • Set the brake • Put the controls in neutral • Remove the key if you will be more than 25’ from the forklift and public access is possible.

  33. Safe Operating Procedures • Never exceed the forklift’s Maximum Lifting Capacity. • Remember – attachments used on the forklift will affect the Maximum Lifting Capacity.

  34. Safe Operating Procedures • NO HORSEPLAY is allowed! • Always slow down when turning. • Make sure the load is stable and won’t • shift while moving. • Always spread forks as wide as possible • for maximum stability.

  35. Safe Operating Procedures • Don’t pick up loads on broken pallets or boxes in bad condition. Transfer the load to a new pallet or box before lifting. • Always keep arms and legs inside the roll over protection system. • Slow down when approaching cross aisles, ramps, dips, uneven or slippery surfaces and congested areas.

  36. Inspection & Maintenance *See the Operator’s Manual for specific inspection criteria.

  37. Inspection & Maintenance • Forklift maintenance should be conducted per the manufacturer’s recommendations. • A daily inspection should be conducted prior to each day’s use. • Remove the forklift from service until proper repair or replacement can be made if defects are found

  38. Other Safety Considerations • Fire extinguishers (if provided on the forklift) must be charged and ready to use. • Back-up alarms must be audible and working. • Be aware of any Administrative practices- ie. policies related to forklift safety

  39. Operational Training • Know where controls are located, what they do, how they work • Inspection test • Obstacle course / Routine function testing

  40. Operational Training • Design a course that incorporates a series of tasks that would be require the operator to repeat the most difficult tasks that he/she would be required to carry out on the lifttruck (including pre-trip inspection and control manipulation) • Operational trainer should be most experience lift operator with a proven good safety rating • Trainer should walkthrough a pre-trip inspection and the “how to” use vehicle controls

  41. Certification Operations and Classroom Evaluations: Pass = Certification • Name of the Operator • Date of Training and Evaluation • Name of Trainer • Listing of material covered

  42. Lawn Mowers- Considerations • (Riding Mowers) Same Requirements as forklifts plus design standards 1910.243 (e) (consumer type mowers)

  43. Lawn Mowers- Considerations 1910.243(e)(1)(i) Power lawnmowersof the walk-behind, riding-rotary, and reel power lawnmowers designed for sale to the general public shall meet the design specifications in "American National Standard Safety Specifications for Power Lawnmowers" ANSI B71.1-X1968, which is incorporated by reference as specified in Sec. 1910.6.

  44. Lawn Mowers- Considerations 1910.243(e)(1)(iii) A shutoff device shall be provided to stop operation of the motor or engine. 1910.243(e)(1)(iv)All positions of the operating controls shall be clearly 1910.243(e)(1)(v) The words, "Caution. Be sure the operating control(s) is in neutral before starting the engine,"

  45. Lawn Mowers- Considerations According to Consumer Product Safety Commission (CPSC), 25,300 people are injured by lawn mowers each year: 75 are killed Two most common injuries: amputations and injuries from thrown objects The speed of debris coming out of the discharge chute has been clocked at 200 miles per hour Push mower should be mowed across a slope; riding mower up and down a slope

  46. Lawn Mowers- Considerations • Know how to operate equipment - Read owner’s manual. Know where controls are and what they do • Dress properly - Wear long pants, safety shoes, and safety glasses (Hearing protection) • Handle gas carefully - Fill up while engine is cold. Don’t spill when you fill. Store gas in approved container in cool ventilated area. Never smoke around gasoline • Clear area before you start - Pick up rocks, twigs, cans hoses, anything that can be thrown by mowing equipment • Follow recommended procedures - Always turn off engine and disconnect spark plug before unclogging or working on equipment • Keep hands and feet from moving parts - Never remove or tamper with safety devices or labels. They are for your protection

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