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Forklift Training(Powered

Industrial Truck)

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Agenda

What is a Powered Industrial Truck?

Basic Engineering Principles

Safe Operating Procedures

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There are over 36,000 injuries

related to forklifts each year!

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Objectives

• Recognize material handling hazards – Manual material handling– Industrial trucks– Conveyors– (Cranes will be addressed later)

• Become familiar with basic methods of controlling these hazards

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Material Handling and Storage

• Outline– Introduction– General Practices– Storage– Manual Material Handling– Powered Industrial Trucks

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Introduction

• General Work Practices– Get help for large loads or use mechanical

devices– When blocking a raised load:

• Keep hands from underneath before releasing load

• Use blocking materials of adequate strength• Look for cracks, splintered pieces, rounded

corners, etc.– Attach handles or holder to loads– Use appropriate PPE

• Gloves, eye protection, safety boots (for heavy loads)

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Introduction

• General Work Practices (cont.)– Do not overload equipment

• Refer to equipment rated capacity– General forklift procedures

• Center load on forks and close to mast• Do not overload• Do not add extra weight to counterbalance• Travel with load at lowest position

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Materials Storage

• Precautions for stored materials– Stacked loads correctly piled and cross-tiered– Stored material must not create hazard– Areas free of accumulated material – In buildings, no stored materials within 6 feet of

hoist ways or 10 feet of exterior building walls– Store non-compatible material separately

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Materials Storage

• Stored material precautions (cont.)– Employees in silos, hopers or tanks equipped with

lifeline and safety harness– Bound material stacked, on racks, blocked or

interlocked to keep it from sliding, falling or collapsing

– Don't exceed load capacity for the structure• Post load limits

– Stacking height• Mark walls or posts to indicate maximum height

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Lumber and Brick Storage

• Lumber– Maximum stack height

• 16 feet (manual handling)• 20 feet (forklift)

– Remove nails from used lumber– Stacks stable and self-supporting

• Bricks– Maximum 7 feet high– Above 4 feet, taper stacks 2 inches per

foot

Lumber storage

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Block and Bag Storage

• Masonry blocks– Above 6 feet , taper stacks 2

block per tier• Bags and bundles

– Stack in interlocking rows– Step back at least every 10

layers– Remove from top of stack first– Keep baled paper and rags at

least 10 inches from walls, ceilings, or sprinkler heads

Block storage

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Box and Drum Storage

• Boxed materials– Hold in place using cross-ties, or

shrink plastic• Block cylindrical material (bars,

poles, etc.)• Use bins or shelves for

materials that cannot be stacked Box storage

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Box and Drum Storage

• Drums, barrels, kegs– Stack symmetrically– If stored on side,

block bottom tiers to prevent rolling

– If stacked on ends, use planks, pallets, etc. between each tier Drum storage

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Powered Industrial Trucks (Forklifts)

• Forklift injuries and deaths– 100 annual deaths, 95,000 injured– Cause of fatality:

• 42% crushed by vehicle tipping• 25% crushed between vehicle and surface• 11% crushed between two vehicles• 10% struck or run over by vehicle

– 8% struck by falling material– 4% fall from platform or forks– 2% accidental activation of controls

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Powered Industrial Trucks (Forklifts)

• Forklift injuries and deaths (cont)– “Classic” forklift accidents:

• Forklift overturns when traveling or lifting a load

• Trailer moves while being loaded or unloaded, causing the forklift to fall

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Powered Industrial Trucks (Forklifts)

• Forklift safety– ANSI Approved

• Identifying label– Owner modification

• Only with mfg. Approval

• New label required– Front-end attachments

• Should have new label

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Classes of forklifts– Electric Motor, Sit-down Rider, Counter-Balanced

Trucks (solid and pneumatic tires)– Electric Motor Narrow Aisle Trucks (solid tires)

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Classes of forklifts– Electric Motor Hand Trucks or Hand/Rider Trucks (solid

tires)– Internal Combustion Engine Trucks (solid tires)

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Classes of forklifts– Internal Combustion Engine Trucks (pneumatic tires)– Electric and Internal Combustion Engine Tractors (solid

and pneumatic tires)– Rough Terrain Forklift Trucks (pneumatic tires)

Rough Terrain Extended-Reach Forklifts

Tractors

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Trucks for Hazardous Locations

• “Explosion proof” forklifts are used to control ignition– Example:

• DS (Diesel), EE (completely enclosed electrical), or EX trucks where flammable gases or liquids are handled, but contained

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Powered Industrial Truck Safety

• Fuel, liquid or gas– Handled in accord with NFPA standards

• Batteries– Hazards

• Lifting and handling• Acid (electrolyte)• Hydrogen produced during charging

– Precautions• Designated battery charging area• Spill control, fire protection,

ventilation, etc.• Mechanical handling equipment• No smoking Battery charging station

Forklift battery

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Powered Industrial Truck Safety

• Trucks and Railroad cars– Many deaths occur when a truck moves

as it is loaded• Forklift travel and braking action cause

the truck to move away from the dock• The forklift falls into the gap and the

driver is crushed– Precautions

• Brakes set, wheel chocks (trucks)• Wheel stops (railroad cars)• Trailer restraints secure the truck to

the loading dock

Wheel chock

Trailer restraint

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Powered Industrial Truck Operation

• Safe forklift operation– Never drive toward a person standing in front of a fixed

object– No person under any elevated portion– Do not place arms or legs in the mast or outside the

truck– Unattended trucks must be shut off with lowered load– Set brakes and wheel blocks when loading vehicles

(trucks, rail cars, etc.)– Maintain headroom under lights, sprinkler systems, etc.– Use overhead guard to protect from falling objects– Use load backrest when necessary

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Powered Industrial Truck Operation

• Safe forklift operation – Cross railroad tacks on the diagonal– Sound horn at blind intersections– Back down ramps, drive forward up ramps– Operate at safe speed, avoid quick turns– Personnel on loading platform must have an

emergency shut-off for truck power– Secure dockboards and bridge plates– Loads must be stable and safely arranged– Disconnect battery before repairing electrical

system– Replacement parts must be equivalent to original

A dockboard is used to bridgethe gap betweenloading dock and truck/trailer

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A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Theoretical)

Stability Triangle:

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.

Forklift Training

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Load CG

Vertical StabilityLine(Line of Action)

Combined CG

Truck CG

Load CG

Combined CG

Vertical StabilityLine(Line of Action)

Truck CG

The vehicle is stable This vehicle is unstable and will continue to tip over

Stability Triangle

Forklift Training

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What is a Powered IndustrialTruck?

• A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials.

• Does not cover vehicles used for earth moving and over-the-road hauling.

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How are PITs different from a car?

• PITs steer from the rear.

• Loads will affect weight and balance.

• PITs weigh 2-3 times more than a car.

• Stability is a concern.

• Refueling may be different.

• Different types of tires.

• Attachments

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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.

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Refueling(gas, propane, diesel)

• Never refuel inside a building.

• Turn off the forklift before fueling.

• No smoking or open flames in the area.

• Wear gloves for propane refueling.

• Wear safety glasses for splash hazards.

• Have a fire extinguisher nearby.

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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?

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Attachments

• All attachments (ex. counter balances, fork extenders, personnel cages, drum attachments, etc.) to forklifts must be approved by the manufacturer!– Attachments may affect the lifting capacity of the forklift,

and should come with a data plate specifying the new maximum lifting capacity.

• Modifications to your forklift and attachments must be approved by the manufacturer!

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Attachments• Personnel cages are

designed to elevate personnel to perform certain duties.

• Never use a pallet (or any other makeshift device) to lift personnel!

This personnel cage has been “illegally” altered – top guardrail was removed – and

can no longer be used.

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Attachments

• Drum attachments are recommended for hauling 55 gallon

drums.

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Attachments

• Fork extenders are sleeves that fit over the existing forks to extend the length of the forks.

• Forklift extenders must not exceed 150% of the existing forks’ length.

For example, if your forklift forks are 4’ in length, the maximum length of the extenders cannot exceed 6’.

4’ x 1.5 = 6’

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Basic Engineering Principles

• To operate your forklift safely, you must first understand a few of the basic engineering principals involved.

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Fulcrum Principle• Forklifts operate on the fulcrum principle.

On a forklift, the fulcrum is located at the front tires.

Forklift’s counter-balance

Load

Fulcrum

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Center of Gravity

• The center of gravity is where all of the weight is concentrated. Consider the center of gravity of the following:– the forklift itself – the load or object you are carrying– the combined weight of the load and the forklift

together

see next few slides…

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A

B

C

The imaginary triangle between the pivot pin in the rear (A) and the two front tires (B and C) forms the stability triangle

on a forklift. As long as the combined center of gravity remains within this area, the forklift will not tip over.

Stability Triangle

Combined Center of Gravity

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A

B

C

Vehicle Center ofGravity (Unloaded)

Center of Gravityof Vehicle and Maximum Load(Loaded)

When the vehicle is loaded, the combined center of gravity (green circle inside the triangle) shifts

toward line B-C.

Stability Triangle

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A

B

C

Standard Load Center

• 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.

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A

B

C

Any load center greater than 24” is considered

an oversized load.

Oversized Loads

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Oversized Loads• Rule of Thumb: For every inch past a

standard load center (24”), the forklift’s lifting capacity will be reduced by 100

pounds.

Example: For a forklift with a maximum lifting capacity of 4000 lbs. and a load center of 30”, the

new maximum lifting capacity is 3400 lbs.

30” – 24” = 6”

6” x 100 lbs. = 600 lbs.

4000 lbs. – 600 lbs. = 3400 lbs.

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Longitudinal Stability

The forklifts’ axis of rotation is the

front tires.

Longitudinal stability is the forklifts’ resistance

to overturning frontward or backward.

For example: lifting a load that exceeds the

maximum lifting capacity.

For example: tipping backwards while going up an

incline.

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Lateral StabilityLateral 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.

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Dynamic Stability

Dynamic stability refers to the stability of the forklift while

moving. The faster you go, the more unstable you become!

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Workplace Hazards– Pedestrians can be a big problem in some areas.

They typically aren’t aware of how a forklift handles – braking, rear end swing – and they may not pay attention to what you’re doing. Give them

the right of way!

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Workplace Hazards

– Surface conditions in your work area may need special consideration. Pot holes, false floors, weight limits, wet floors, loading docks, etc. can all affect your stability and/or braking distance. Be aware of

these situations and avoid them!

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Workplace Hazards

– Know what you’re 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.

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Workplace Hazards

– Work areas with poor ventilation could cause carbon monoxide or diesel exhaust buildup.

– Open doors to ventilate if necessary or purchase an electric-powered forklift if the opportunity arises.

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Loading Docks• Avoid driving too close to the edges of loading

docks. Concrete can chip or you may not be able to see how close you are to the edge.

• Trailer wheels must be chocked and truck brakes applied.

• Dock plates:– Know the capacity.

– Good condition?

– Properly placed?

– Secured?

Dock Plate

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Ramps and Inclines

• For forklifts, always keep the load uphill.– Drive up and back down.

• For pallet jacks, always keep the load downhill.

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Safe Operating Procedures

• Speeding is the number 1 violation regarding forklifts.

• Forklifts are not designed for speed – 5 mph, or about walking pace, is recommended! X

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Safe Operating Procedures

• Cross speed bumps or train tracks at an angle - slowly!

• Always look in the direction of travel.

• Sound horn at blind corners to warn others

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Safe Operating Procedures

• Riders are not allowed!• Wear your seat belt!

– It will keep you within the forklifts’ rollover protection system, which is the safest place to be in the event of a tip over.

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Safe Operating Procedures

• Parking:– Lower forks to

ground,– Set the brake,– Put the controls in

neutral, and– Remove the key if

you will be more than 25’ from the forklift and public access is possible.

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Safe Operating Procedures

• Never exceed the forklift’s Maximum Lifting Capacity. This capacity can be found on the forklift’s data plate, which can be found on the forklift itself.

• Remember – attachments used on the forklift will affect the Maximum Lifting Capacity.

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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.

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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.

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Inspection & Maintenance

*See the Operator’s Manual for specific inspection criteria.

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Inspection & Maintenance

• A daily inspection should be conducted prior to each day’s use.

• EHSS recommends that you document your inspections!

– See the operator’s manual or EHSS for a sample form.

• Forklift maintenance should be conducted per the manufacturer’s recommendations.

• Remove the forklift from service until proper repair or replacement can be made if defects are found that may affect the safe operation of the truck!

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Other Safety Considerations• Fire extinguishers (if provided on the

forklift) must be charged and ready to use.– Operator’s must have Portable Fire

Extinguisher training.

• Back-up alarms must be audible and working.

• Directional lighting, flashing lights, and other signs and signals may be required for use on roadways or similar situations.