1.BY R.V.Mutusamy.

2. The following topics will be covered How a forklift operates Hazards of forklift operation How to use forklifts safely 3. Forklift is a machine used to transport heavy materials from one place to another place (Short distance only) to stack, unstack, to load & unload material. 4. Forklift is capable to lift heights under 30 feet. Load 1ton to 5ton in height 5. OVERHEAD GUARD MAST CARRIAGE BACKREST LIFT CYLINDER TILT CYLINDERS FORKS LOAD CAPACITY 6000 lbs PROPANE ONLY 6. Only Trained authorized personnel are permitted to operate a forklift. Badges or other visual indications shall be displayed on the body of the operators at all time during operation. The operator should not drive the truck up to a person standing in front of a bench or other object. The operator should not carry loads heavier than those for which the truck rated. 6 7. Forklift controls operated only from drivers seat Never block exits or emergency equipment Smoking is not permitted when operating the forklift No person should stand under elevated portion of lift truck 7 8. The operator should avoid making fast starts, sudden stops and quick turns. The operator should report all accident involving personnel, building structures and other equipment. Operation on main roads outside the factory premises should be permitted only with proper authorization of local transport authority. Unless specifically authorized to do any repair, the operator should not make repairs, alterations or adjustments to the 8 9. Workplace hazards: ramps, slippery floors, poor lighting, congestion Loads: large or bulky, uneven weight, broken pallets, poor stacked Pedestrians: horseplay, unaware of forklift areas, not paying attention 10. Almost all counterbalanced powered industrial trucks supported at three points. This is true even if the vehicle has four wheels. The truck's steer axle is attached to the truck by a pivot pin in the axle's center. When this point is connected to the front wheels with imaginary lines, this three-point support forms a triangle called the stability triangle. So long as the center of gravity remains within this stability triangle, the truck is stable and will not tip over. 11. A forklift balances a load with a counterweight at the back. The front wheels act as a pivot or balance point. The center of gravity moves upward when the forks are raised. 12. While carrying a load near the maximum allowable capacity, be aware of the following: Danger of tip over Danger of losing load Danger of being struck by falling load 13. LIFTING PRINCIPLE CONSULT YOUR VEHICLE OWNERS MANUAL 6500lbs REAL HEAVY PARTS INCORRECT CORRECT 6500lbs REAL HEAVY PARTS 14. Loose loads are subject to falling. Off center loads can also be subject to falling or cause the forklift to tip over. The photos below show the correct way to load pallets. Avoid using damaged pallets. 15. Before raising a load, understand: Approximate weight of the load Location of the loads center of gravity Inspect load for stability, projections, damaged pallets before lifting Restack unstable loads Never place weight on the back of a lift truck to increase its capacity Towing always done from rear towing pin 15 16. When removing a load from a high rack: Slowly back out with the load Stop when it clears the rack Lower the load to the floor Dont lower the load while moving! 17. Use extra caution when handling loads that approach the truck's maximum rated capacity: Tilt the mast & forks back and position the heaviest part of the load against the carriage. Travel with the mast tilted back to keep the load stable. Never travel with the load tilted forward. Tilting the load forward increases the load distance and makes the load less stable 18. Always drive with the load on the uphill side - go backwards driving down the incline and frontwards going up the incline to prevent tipping or losing control of the forklift. If no load on the forklifts, do the opposite with forks pointing down the ramp 19. Driving too fast around a corner Driving off edge of platform, ramp, road or other surface Driving an indoor forklift outdoors on rough, uneven ground Turning on an incline or hill 20. Do not jump Hold onto the steering wheel Brace your feet Lean away from the fall 21. Slow down and sound horn at intersections, corners, and wherever your vision is obstructed. When provided, use flashing warning light or backup alarms when traveling in reverse. Always look in the direction of travel. Signal to pedestrians to stand clear. Do not allow anyone to stand or walk under upraised forks. When possible, make eye contact with pedestrians or other forklift operators before moving in their path. 22. Give them warning with sensible one 23. No one else on the forklift except the operator, unless the forklift has a seat for a rider. Always drive with the forks lowered and lower forks to floor when parking the forklift. Watch overhead clearances especially entering or exiting buildings or when you are raising a load on the forks. 24. Wheres the operator?? 25. Pedestrians and forklift moving in same place 26. Worn out tyres 27. IF YOU ARE GOING OPERATE A FORKLIFT: DONT DRINK ALCOHOL DONT USE DRUGS - DONT PUT YOUR LIFE AND THE LIFE OF YOUR COLLEAGUES IN DANGER 28. 28 29. Forklift properly disconnected Forks down, key off, neutral gear, parking brake on Left/right side Tire condition, tight lug nuts, no debris around axle, overhead guard is solid, no debris behind the mast Front Forks in good shape, fork pins in place, backrest solid, mast & chains greased, hoses in good shape Rear Counterbalance bolt is tight, radiator clear of debris29 30. Non-moving checks Gauges, lights, horn, Reverse alarm, blinking warning light, operate the tilt & lift mechanism, check the parking brake Moving checks Check the running brakes, check the steering Look for oil or water leaks on the floor Daily check list 30 31. Always look in the direction of travel Keep body inside the cage When moving, the mast must not be raised Sound the horn Operate at safe speeds When turning, watch rear end swing Clearance under overhead installations 31 32. 32 Report to your supervisor on any forklift damage or problems Dont use a forklift to lift worker Use caution on slopes or ramps While on slopes, tilt the load back and raise it above road surface Dont raise or lower the forks while the forklift is moving Dont handle loads that are above the weight capacity of the forklift Follow the speed limit 33. 33 Slow down and sound the horn at crossings and locations where view is blocked Focus on the travelling path and keep a clear view of it When leaving a forklift, pull the parking brake, lower the forks and neutralize the controls Slow down and sound the horn at crossings and locations where view is blocked Focus on the travelling path and keep a clear view of it 34. 34 The engine of diesel forklift should be stopped before refueling. It should not be restarted unless the fuel line has been removed from the forklift and the filler cap has been properly replaced on the tank. Particular attention should be paid to avoid fuel spilling over the engine or exhaust system. If spillages occur the fuel should be wiped away properly before restating the engine. Contact between the metal outlet of the refueling hose and the fuel tank opening on the forklift should be maintained at all time during refueling process. Naked flames should never be used to check fuel levels in tanks. 35. 35 1 Does the forklift specification meet the operating requirement? 2 Is forklift maximum load capacity clearly printed on the forklift body? 3 Does the forklift maximum speed controlled? 4 Do horn, reversing beeper, proximity indicator and flashing light function properly? 5 Are the forklift maintenance performed regularly? 6 Are forklift maintenance and repair records maintained? 7 Are the tires in good conditions? 8 Forklift breaks conditions 9 Is the steering work well? 10 Does the gear control work? 11 Are the left, right and rear view mirrors available and clear? 12 Do all indicators and gauges function properly? 13 Are there any liquid leaks from the forklift? 14 Are Mast, Lifting system are in good condition? 36. 36 Workplace Premise: Warehouse premise in a distribution park Forklift: 3 ton (load capacity) Work Activity: Deceased was taking stock of goods to be transported out of the warehouse. He squeezed through the gap between two racks and was crushed when a forklift pushed the racks closer to make space for more racks. Nature of Accident: Crushed between objects 37. 37 Description of Accident The deceased worker was involved in tallying stock stored on metal racks within yellow boxes. 38. 38 The deceased worker was conducting checks in between two metal racks just prior to the accident. To free up space for more cargo, a forklift operator used his forklift to push the adjacent metal racks. The deceased worker was trapped in between the metal racks. Deceased worker was found dead an hour later. 39. 39 40. 40 41. 41 Key Findings / Observations 42. HOW MANY SAFETY METHODS? Accident / Incident Investigation Accident Statistics Asbestos Behavioural Safety Construction Control of Contractors COSHH Culture Diploma Unit A Diploma Unit B Diploma Unit C Diploma Unit D Disability Discrimination Act (DDA) Display Screen Equipment - DSE Driving Electricity Environmental Ergonomics Excavations Fire Safety General Tools Hands Law 43. HOW MANY SAFETY METHODS? Lifting Operations and Lifting Equipment - LOLER Management of Health and Safety Manual Handling Noise Occupational Health OHSAS PAUSE Permit to Work Personal Protective Equipment (PPE) Policy Practice Questions and Answers Provision and Use of Work Equipment (PUWER) Reporting RIDDOR Risk Assessment Safety Induction Signage Stress Terrorism Training Tools Travel Work at Height Workplace Transport