Forklift Operator Training

1. Forklift Operator Training

2. Powered Industrial Truck - Definition • A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials (American Society of Mechanical Engineers [ASME] definition). • Excluded are vehicles used for earth moving and over-the-road hauling. • Commonly known as forklifts, pallet trucks, rider trucks, forktrucks, or lift trucks. • Can be powered through electric or combustion engines.

3. Forklifts Are Used Everywhere! • Warehouses • Manufacturing Plants • Construction Sites • Loading Docks • Shipping and Receiving

4. Industries Where Powered Industrial Truck Accidents Occurred Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and Mechanical Engineering Safety Standards.

5. OSHA Requires Trained Competent Operators on Forklifts • All Forklift Operators must be trained and certified by their employer prior to operating forklifts. The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation. • Classroom training must cover principles of forklift operation with a hazards and controls review. • Operators must also have their skills tested through a Skills Evaluation. Prevent Forklift Accidents Learn to Operate Safely!

6. What Does It Take To Be Safe? • You • Your Vehicle • Your Attitude

7. You • Be prepared: • Physically • Mentally

8. Your Vehicle - “Condition” • Inspections • Preventive maintenance • Reporting noted items and assuring they are corrected • Application - right for environment

9. Your Attitude Your Attitude or Approach: Safe Behavior

10. Fatalities Resulting from Forklift Accidents • Once every three days in the U.S. • This is in addition to about 95,000 other injuries caused by forklifts every year. • OSHA calculates that about 70% of these accidents could be avoided with proper safety training.

11. Forklift Fatalities by Age Group Source: Bureau of Labor Statistics

12. Non-Fatal Occupational Injuries and Illnesses by Source Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.

13. Goals and Objectives • Goal – To reduce the number of critical behaviors and conditions which occur while operating forklifts: • Discuss principles of forklift operation including how to complete a forklift inspection. • Review capacity plate use and try sample problems. • Review OSHA safe operating requirements. • Evaluate the Job Safety Analysis for forklift operators including pre-lift, lift & move, and set down procedures. • Complete a test to evaluate knowledge.

14. Forklift Use Starts with Inspection • Daily Operator Checklist to be completed prior to first use Check hoses and Cylinders Check Fuel Sources Check all controls Check Brakes Check Steering Capacity Plate • Pick a tire and Walk Around • Check Tires for damage • Check for leaks • Check hoses and cylinders & Fuel Source • Check Lights • Check for Load Chart & Extinguishers • Get Into Forklift • Check Controls and Brakes • Check Lights • Check Gauges Check under engine and lift device for leaks Check Tires Rims and Lug nuts • Fasten Seatbelt and Work!

15. Types of Forklifts • Configurations – Stand, Sit, Walk, Ride • Fuel Types – Electric, Gasoline, Diesel, Propane. • Tire Type – Pneumatic or Hard • Terrain – 4 x 4 Rough Terrain, Warehouse Only, etc. • Powered Pallet Jacks Specialized Attachments • Others

16. Classes of Commonly Used Powered Industrial Trucks • 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.

17. Forklift Designs and Uses • The two front wheels and the center of the rear axle form a STABILITY TRIANGLE. • The center of gravity must remain inside the triangle or the lift truck will tip. • The higher the load, the smaller the triangle gets and the easier it is to tip. Triangle with High Mast Center of Gravity (COG) • The faster you go, the more the center of gravity travels, getting closer to the triangle edge, making it easier to tip.

18. Capacity Plates and Lift Limits • All lift trucks must have a capacity plate. Mast height from floor to forks • Usually require three items to determine capacity: • Load Weight • Load Center • Height of Lift (mast height) LOAD • Always use next lower capacity if load falls between two. Load center – Backrest to Balance point of load • Load center is measured from backrest of forklift.

19. Car vs. Forklift - Differences • Size • Traction • Weight added • Suspension • Moving center of gravity • Rear wheel steering • Forks protruding

20. Stability Triangle Vehicle Center of Gravity (Unloaded) B A Center of Gravity of Vehicle and Maximum Load (Theoretical) C Notes: 1. When the vehicle is loaded, the combined center of gravity (CG) shifts toward line B-C. Theoretically the maximum load will result in the CG at the line B-C. In actual practice, the combined CG should never be at line B-C. 2. The addition of additional counterweight will cause the truck CG to shift toward point A and result in a truck that is less stable laterally.

21. Stability Triangle Load CG Load CG Vertical Stability Line (Line of Action) Combined CG Combined CG Vertical Stability Line (Line of Action) Truck CG Truck CG This vehicle is unstable and will continue to tip over The vehicle is stable

22. Stability Triangle/Capacity Plate

23. Stability Triangle/Counter Weights

24. Stability Triangle

25. Stability Triangle

26. Stability Triangle

27. Stability Triangle

28. Determining the Weight • Shipping Documentation • On the item or on the product (a pallet of 100 50# bags of concrete for instance) • From Weight & Measure Standards: • Wood – by foot for dimensional lumber, wet or dry, wood type • Steel – by for for structural, by square foot for plate, sheet, etc. • Others • Little Black Book of Standards

29. Weights (lbs. for 1x12x12 inches) • Steel= 40.8384 • 1100 Aluminum= 14.1382 • 300 SS= 42.0635 • Copper= 46.7191 • Lead= 59.1340 • Gold= 100.7074

30. Inch Pound Equation Example

31. Inch Pound Equation (Cont’d) • You operate a lift truck that is rated at 5000 lb @ 24 inch LC. • You must lift a load with an LC of 36 inches. The distance from the center of the front wheels to the face of the forks is 18 inches. • What is the maximum weight you can lift?

32. Inch Pound Equation (Cont’d) To solve the problem, you must break it into two steps: Step 1: You must determine the maximum Inch Pound capacity of the truck. To do this, you must use the equation - (A + B) x C = Inch Pound, where A = 18”, B=24”, and C = 5000 lb. A B

33. Inch Pound Equation (Cont’d) (18” + 24”) x 5000 lb = Inch Pounds (42”) x 5000 = 210,000 Inch Pounds NOTE: The distance from the fulcrum to the face of the forks will vary depending on the size of your truck and the attachments installed.

34. Inch Pound Equation (Cont’d.) To determine the (A) dimension for your truck, measure the distance from the center of the front wheels to the front face of the fork.

35. Inch Pound Equation (Cont’d.)

36. Inch Pound Equation (Cont’d.) Step 2: Once you have determined the maximum Inch Pound capacity of the truck, you must now determine a new lift capacity for the truck using a Load Center of 36” instead of 24”. Again, you need the equation: (A + B) x C = Inch Pounds.

37. Inch Pound Equation (Cont’d.) Where A = 18”, B = 36”, C = ? Lb. and Inch Pounds = 210,000 (18” + 36”) x ? = 210,000 I.P. (54”) x ? Lb. = 210,000 I.P.

38. Inch Pound Equation (Cont’d.) To determine the new capacity, divide 210,000 Inch Pounds by 54”. ? Lb = 210,000 Inch Pounds /54” The lift capacity at a 36 inch load center is 3,888 lb.

40. Break

41. Safe Operating Rules and Practices • OSHA Rules • Job Hazard Analysis Rules • Rules of refueling gas • Rules for recharging batteries • Rules for refueling propane

42. Ensuring a Safe Ride • Only YOU the operator can ensure the forklift is operated safely. • Conduct a pre-check. • Know your route of travel. • Don’t use un-safe equipment.

43. Forklift Use Starts with Inspection • Daily Operator Checklist to be completed prior to first use Check hoses and Cylinders Check Fuel Sources Check all controls Check Brakes Check Steering Capacity Plate • Pick a tire and Walk Around • Check Tires for damage • Check for leaks • Check hoses and cylinders & Fuel Source • Check Lights • Check for Load Chart & Extinguishers • Get Into Forklift • Check Controls and Brakes • Check Lights • Check Gauges Check under engine and lift device for leaks Check Tires Rims and Lug nuts • Fasten Seatbelt and Work!

44. Pre-check • Conduct a safety check at the start of each day or the first time you use the equipment for the day. • The checklist ensures YOUR safety.

45. Pre-shift Inspections As stated in OSHA Regulations “Industrial trucks shall be examined before being placed in service, and shall not be placed in service if the examination shows any condition adversely affecting the safety of the vehicle. Such examination shall be made at least daily.”

46. Pre-shift Inspections (Cont’d.) OSHA has made it quite clear that these inspections are to be carried out on a regular basis. Keep in mind that the only way to prove that these inspections are being done is to record them.

47. Pre-shift Inspections (Cont’d.)

48. Pre-shift Inspections (Cont’d.) It is highly recommended that the operator fill out a pre-shift inspection form to be retained by the company as proof that this regulation is being complied with at the site.

49. Parts Know your equipment: • Controls • Adjustments • Load Rating • Overhead clearance • Side Clearance

50. Parts *One of the most common types of powered industrial trucks