Powered Industrial Forklift Training Part I

WELOME TO
OSHTI PLC
Authorized Training Provider # 2015180017

Powered Industrial
Forklift Training: Part I
OSHACADEMY COURSE 725

Contact t:237 673039494
email: vitalis@oshti.orge.jeanterrye.jnterry1@gmail.com 1@gmail.com
Instructors: Vitalis Alah Mocho

Presentation
 And you, What’s your Name
 What do you do in your company
 What are your expectations for
this training
 Now we know each other
Occupational Safety & Health Training Institution Plc. 4

Safety Moment & Ground Rules
 Where are Emergency exits & muster point
 Listen and share your experiences
 If you are not sure ASK
 Actively take part in the workshop
 Turn off mobile phones and beepers
 No side conversations
 Strictly respect break and return timings
 Have fun, humour is good
 Enjoy your training session
Occupational Safety & Health Training Institution Plc. 5

TRAINING PROGRAM OUTLINE
 Introduction: Day 1
 Types, Features, and Physics
 Inspecting the Forklift
 Driving the Forklift
 Load Handling
 Battery and Charging
 Safety Concerns
 Practical Exercise Forklift: Day 2
 Practical Exercise Tele-handlers: Day 3

A powered industrial truck is defined
as a mobile, power-driven vehicle
used to
– carry
– push
– pull
– lift
– stack Load
CHARACTERISTICS OF THE POWERED
INDUSTRIAL FORKLIFT (S)
Norlift of Oregon, Inc.

General Requirements &
Designations
Compliance with ASME B56.1
(Formerly ANSI B56.1-1969)
 ASME B56.1-1993 is newest
All nameplates and markings must
be in place and legible.

All modifications
and additions
which affect the
safe operation
and capacity
must be
approved by the
manufacturer.

If using front-end attachments (other
than the manufacturers’), the forklift
must be marked to:
 identifying the attachment
 listing the approximate combined
weight of the truck and
attachment at
maximum
elevation with a
centered load

D Diesel powered
DS Diesel with additional safeguards
to exhaust, fuel, and electrical
DY Diesel with all
safeguards;
temperature limit
features; and no
electrical
equipment
Types of Industrial forklift
Norlift of Oregon, Inc

E Electrically powered
ES Electric with additional
safeguards to electrical system
EE Electric with all safeguards
and intrinsically safe
EX Electric and can be
used in atmospheres
containing flammable
dusts & vapors

G Gasoline powered
GS Gasoline powered with added
safeguards to the exhaust, fuel,
and electrical system

LP Liquefied petroleum
powered
LPS Liquefied petroleum
with additional safeguards to
exhaust, fuel, and
electrical
CNG Compressed natural gas

Overhead Guards
What does FOPS protect you from?
“Stuff” falling from your load!
• small boxes
• containers
• bagged material
• drums

Overhead Guards
What does FOPS not protect you from?
• really small stuff such as:
• Grains
• Dust
• Rains
• Sand etc.
•The impact of a fallen
capacity load

Other Design Features
• Must be large enough to extend
over the operator under normal
circumstances
• Guard openings must not be
larger than six inches in one of the
two dimensions
• Must not interfere with your
visibility

 A Load Back Rest must be
provided when handling small
objects or unbanded units
Load Back Rest
• openings no wider than 6 inch.
• must not obstruct your visibility
• must be able to prevent the
load, or any part of the load,
from falling toward the operator

The lift truck is based on the principle
of two weights balanced on opposite
sides of a pivot - fulcrum point
Stability
FULCRUM

For this principle to work, the load of
the forks must be balanced by the
weight of the lift truck.
• The properly loaded
lift truck does not
exceed the rated
capacity of the truck
– listed on the
data plate
Stability

The center of gravity (CG) of any
object is the single point about which
the object is balanced in all directions.
• Every object has a CG
When the lift truck picks up a load, the
truck and load have a new combined
CG.
Stability

The stability of
the lift truck is
determined by
the location of
its CG, or if
the truck is
loaded, the
combined CG.
Stability is Key!
Stability

For the lift truck to be stable, the CG
must stay within the ______ ______.
Stability

For the lift truck to be stable, the CG
must stay within the stability triangle.
Stability

If the CG moves forward of the drive
axle, the truck will tip forward.
Stability

If the CG moves outside of the lines to
the side, the lift truck will tip to the
side.
Stability

What factors have caused trucks
to tip forward?
Stability

– mast too high
– exceeding capacity
– heavy braking
– load placed forward of load center
– excessive forward tilt
– tire pressure
– traveling down an incline w/ load
forward
– front end attachment
– driving off docks
Stability

What factors have caused trucks to tip
over on their side?
Stability

– load shifted to the side
– unequal tire pressure
– turning
– speeding
– unlevel terrain
– off-center loads
– mast too high with rear tilt
Stability

The overall stability of the loaded
Forklift is affected by a number of
factors including:
• size
• weight
• shape
• position of the load
Stability

Also:
• height to which the load is
elevated
• the amount of forward or
backward tilt
• tire pressure
• and the dynamic forces
created when the truck is
moving
Stability

These dynamic forces are caused
by:
• acceleration
• braking
• operating on uneven surfaces
• operating on an incline/ramp
• turning
Stability

These factors must be considered
when traveling with an unloaded truck
because...
Stability
an unloaded truck will tip over to
the side easier than a properly
loaded truck.

What is load center?
CENTER OF THE LOAD
The distance from
the heel of the
forks to the center
of the load is
called the
Load Center.
24”
Stability

Load Center? _____
Load Center? _____
Load Center? _____
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
Capacity per data plate = 8050#
Load Center? _____
Load Center? _____
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
Load Center = 24”
Load Center? _____
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
Load Center = 24”
Load Center = 30”
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
SAFE
Load Center = 24”
Load Center = 30”
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
SAFE
Load Center = 24”
SAFE
Load Center = 30”
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

Load Center = 20”
SAFE
Load Center = 24”
SAFE
Load Center = 30”
UH OH!
7000”
7000”
7000”
40”
40”
40”
40”
40”
40”
No
Pallet
48”
Pallet
60”
Pallet

• The capacity is shown on the data
plate
• The capacity is listed in terms of
weight and load center at a
specified load height
• The operator must determine
whether or not a load is within the
capacity of the lift truck before the
load is handled!
Stability

And remember
capacity &
angle when you
operate an
extended boom
forklift!
The Halton Co.

When?
Where?
Seat Restraints

Thompson & Johnson Equipment Co. Inc.
The leading
cause of
death to
forklift
operators is
overturn
Seat Restraints

• Buckle Up!
• Lean Forward!
• Hug The Steering Wheel
• Lean Away From Impact!
Seat Restraints

Module 6
Fuel & Battery
Charging

Battery charging must be done in a
designated area
Protect charging device(s) from
damage
Provide adequate ventilation
Use a hoist or other device(s) when
handling batteries
Fuel & Battery

When charging and fueling, set
brakes!
No open flames, sparks, or electric
arcs! NO Smoking!
Wear personal protective equipment
Fuel & Battery

What must be done when loading
trucks, trailers, and rail cars?
Loading Trucks, Trailers,
& Rail Cars
Hyster Co.
• Trailer brakes set and wheels
choked

Loading Trucks, Trailers, &
Rail Cars
Hyster Co.
• Inspect the
trailer floor
for weakened
sections, holes,
rot, and slick
conditions

Loading Trucks, Trailers, &
Rail Cars
• Directional lighting
• Correct use of dockplate
– secured/anchored
– know capacity

Ensure the load does not exceed the
forklift’s capacity.
Ensure forks are positioned properly.
Ensure the load is balanced and
secure.
Ensure bottom of the load
is raised to the proper
traveling height.
Picking Up A Load

Drive as far into the load as possible.
Slightly tilt back and lift.
Before backing up, check behind and
on both sides for pedestrians or other
traffic.
Back, stop, and lower load 2-6 inches
from the floor.
Picking Up A Load

The operator and pedestrians must
communicate!
Traveling With A Load

No riders/passengers!
Travel at walking speed
All traffic regulations must be met,
including plant speed limits
Maintain at least 3 truck lengths
Be aware of the traveling surface and
keep the load slightly off grade

Avoid sudden braking
Turn in a sweeping motion
Keep the load slightly tilted back
Sound horn when approaching corners
and blind areas

Lift and lower the load only when
stopped
Drive up and
back down
inclines and
ramps

Completely stop before raising a load
Never walk, stand, or allow anyone to
pass under a raised load
Move slowly after raising the load
Tilt forward, level only when over a
stack or rack
Placing & Stacking A Load

Always stack the
load square and
straight

Make sure forks have cleared the
pallet when backing out and before
turning or changing height
Before backing up, check behind and
on both sides for pedestrians or other
traffic
When handling off center loads -
Be Cautious!!

Only loads within the rated capacity
must be handled
Trucks equipped with attachments
must be operated as partially loaded
trucks even when unloaded
Avoid running over loose objects
More Safe Operations

Under all travel conditions, the truck
must be operated at a speed that will
permit it to be brought to a stop in a
safe manner
No horseplay or stunts
If the load is high
obstructing forward view
- drive in reverse

Cross railroad tracks diagonally
Never park closer than eight feet from
tracks
Right of way must be given to
emergency vehicles
Keep arms & legs from the mast and
within the running lines of the truck

Never drive up to someone standing
next to a fixed object
Powered hand trucks must enter
enclosed areas load end forward

Never pass another truck traveling in
the same direction at blind corners,
intersections, or other dangerous
areas
When truck is left unattended:
– lower forks
– neutralize controls
– shut off
– set brakes

• Work platform equipped with fall
protection
Lifting People

Lifting People
• Platform firmly secured to the
carriage or forks
• Falling object protection
• Operator must attend lift truck
while workers are on it and be in
normal operating position when
raising & lowering platform
• A guard must be provided
between workers and mast

Lifting People
Maintain
stability!
Think
capacity!
Hydraulic system must not allow the
lift mechanism to drop faster than 135
ft/min

Lift trucks are required to be
removed from service when not in
safe operating condition.
What do you consider unsafe
operating condition?
Maintenance

Broken/inoperable gauges
Defective/unadjusted brakes
Damaged overhead guard/LBR
Play in steering
Sparks from exhaust
Inoperable horn
Fluid leaksDamaged chain anchor pin
Worn tires/rim damage
Damaged mast chain
Not running wellDislodged counterweight
Defective controls
Missing/nonlegible data plate
Cracks/defects in mast/structure
Wear/defects in the forks/carriage

Who is authorized to make repairs on
your trucks?
Maintenance

How often must lift trucks be
inspected?
What must the inspection cover?
Who conducts them?
Can parts provided from other
manufacturers be used?
Maintenance

MICO Brakes (MICO Locks)
This lever locking brake application
device is not a substitute for the
mechanical parking brake.

Training
• OSHA revised the operator
training rule on 12/01/98
• Oregon OSHA adopted this rule by
reference effective 5/26/99

Only trained and authorized operators shall be
permitted to operate a powered industrial truck.
Methods shall be devised to train operators in
the safe operation of powered industrial trucks.
The Old Rule:
Before - After

 Implementing a training program
 What the training must contain
 Periodic evaluation
 Retraining
 “Certification” of training
 Avoidance of duplicative training
 Information on stability
The “New” Rule:
Before - After

Training
Each powered industrial truck operator must be
competent to operate a powered industrial truck safely.
What is your definition of competent?

Trainees may operate a powered
industrial truck only under the direct
supervision of persons who have the
– knowledge
– training
– experience
to train operators
and evaluate their
competence.
Training

Operator training must consist of a
combination of:
1. Formal
2. Practical
3. Evaluation of
performance in
the workplace
Training

What safety instruction would you
provide to the employees exposed to
lift truck traffic?
Training

All operating instructions, warnings,
and precautions
Differences between the truck and the
automobile
Controls and instrumentation: where,
what, & how
Truck-Related Topics:
Training

Engine or motor operation
Steering and maneuvering
Visibility (restrictions)
Fork and attachment
adaptation, operation,
and use limitations
Training

Vehicle capacity (weight and load
center)
Vehicle stability
(with and w/out
load and
attachments)
Training

Vehicle inspection & maintenance the
operator will be required to perform
Refueling and/or charging and
recharging batteries
Any other operating instructions,
warnings, or limitations listed in the
operator’s manual
Training

Surface
conditions
where the
vehicle will be
operated
The Halton Co.
Workplace-Related Topics:
Training

Composition of probable
loads and load stability
Load manipulation,
stacking, and
unstacking
Training

Pedestrian traffic in areas where the
vehicle will be operated
Narrow aisles and other
restricted places
Operating in hazardous
(classified) locations
Training

Operating the vehicle in closed areas
accumulating exhaust
Operating the truck on ramps and
other sloped surfaces
Unique or potentially hazardous
environmental conditions
Training

Retrain when:
– the operator has been observed to
operate the vehicle in an unsafe
manner
– the operator has been involved in
an accident or near-miss incident
– the operator has received an
evaluation that reveals he/she is
not operating the truck safely
Training

Retrain when:
– the operator is assigned to
operate a different type of truck
– a condition in the workplace
changes in a manner that could
affect safe operation of the truck
Training

And don’t overlook this requirement!
An evaluation of the effectiveness of
the training must also be done!
When? Why? How?
Training

An evaluation of the performance of
each powered industrial truck operator
must be conducted at least once every
three years.
And here’s another evaluation!
Where?
Why?
How?
Training

Observe/audit their performance while
they’re working
– performing the duties they get
paid for
…like loading, stacking,
fueling/charging, inspecting,
pedestrians, parking/shutting down,
maneuvering, horn, ramps, ALL
traveling, using attachments, tiering,
visibility, lifting, lowering, etc.
Training

Follow this up with Q&A, quizzes, etc.
May take an hour(s), all day, different
times of the week
You must evaluate all of their
duties/tasks!
Training
This is basically a continuing
demonstration of safety skill and
knowledge.

What must be documented?
1. Name of the operator
2. Date(s) of the training
3. Date(s) of the evaluation
4. Name of the person(s) performing
the training/evaluation
Employers must “certify” that each
operator has been trained and
evaluated as required by this rule.
Training

If an operator has previously received
training in a topic specified under the
training program content criteria, and
such training is appropriate to the
truck and working conditions
encountered, is additional training in
that topic required if the operator has
been evaluated and found competent
to operate the truck safely? NO
Training

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