FORKLIFT FORKLIFT OPERATOR QUALIFICATION OPERATOR QUALIFICATION

PROGRAMPROGRAM

Objectives of this courseObjectives of this course

• To become qualified to operate a forklift To become qualified to operate a forklift (aka forktruck or Powered Industrial Truck)(aka forktruck or Powered Industrial Truck)

• Learn the rules for safe operationLearn the rules for safe operation

• How to avoid forktruck accidentsHow to avoid forktruck accidents

• How to prevent high maintenance costHow to prevent high maintenance cost

• Verify your understand of what you learned Verify your understand of what you learned with a quizwith a quiz

Causes of AccidentsCauses of Accidents

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Causes of FatalitiesCauses of Fatalities

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Qualification ProgramQualification Program

• This program is not designed to "teach" This program is not designed to "teach" employees how to operate a forklift. employees how to operate a forklift.

• It is intended only to confirm the safety It is intended only to confirm the safety aspects of forklift operation for those aspects of forklift operation for those people already familiar with its operation.people already familiar with its operation.

Who Can Use A Lift Truck?Who Can Use A Lift Truck?

““Only trained and authorized personnel Only trained and authorized personnel shall be permitted to operate forklifts.”shall be permitted to operate forklifts.”

Training requirementTraining requirement

• Phase 1: Classroom instruction & quizPhase 1: Classroom instruction & quiz• Phase 2: Observation of the trainee operating a Phase 2: Observation of the trainee operating a

truck truck by a person experienced in forklift operationby a person experienced in forklift operation

Notes about Phase 2:Notes about Phase 2:– training must not endanger the trainee or other training must not endanger the trainee or other

employees.employees.

– the observation must be completed on each truck the the observation must be completed on each truck the employee will be assigned to operate.employee will be assigned to operate.

Refresher training is required when . . . Refresher training is required when . . .

• The operator has been observed operating in an The operator has been observed operating in an unsafe mannerunsafe manner

• The operator is involved in an incident or near-The operator is involved in an incident or near-missmiss

• The operator is assigned to operate a different type The operator is assigned to operate a different type trucktruck

• A condition in the workplace changes in a manner A condition in the workplace changes in a manner that could affect safe operation of the truck.that could affect safe operation of the truck.

• At least every 3 years.At least every 3 years.

HIGH ACCIDENT & HIGH ACCIDENT & MAINTENACE COSTSMAINTENACE COSTS

Are usually results of :Are usually results of :

• Safety rule violationsSafety rule violations

• Near misses Near misses

• Hot-DoggingHot-Dogging

• Lack of inspectionsLack of inspections

General RequirementsGeneral Requirements

• Modifications or additions to forklifts must Modifications or additions to forklifts must be approved, in writing, by the manufacturerbe approved, in writing, by the manufacturer

• Name plates must reflect all front-end Name plates must reflect all front-end attachmentsattachments

• Nameplates must be in place and legibleNameplates must be in place and legible

• Truck shall not be used around flammable Truck shall not be used around flammable vapors or hazardous concentrations of metal vapors or hazardous concentrations of metal dust dust unless they are designated as a DY, unless they are designated as a DY, EE, or EX EE, or EX

• Attention should be paid to carbon Attention should be paid to carbon monoxide (CO) levels in work areas where monoxide (CO) levels in work areas where truck are operatingtruck are operating

General Requirements (cont.)General Requirements (cont.)

Load CenterLoad Center

Load center

MAXIMUM LOADMAXIMUM LOAD• There will be several weights stenciled on There will be several weights stenciled on

the nameplate.the nameplate.

• The weights listed will be with the uprights The weights listed will be with the uprights vertical and the center of gravity of the vertical and the center of gravity of the load at various distances from the load at various distances from the backrest.backrest.

4350# with load center 24” from backrest

24 4350

Name PlateName Plate

Capacity Load Center

Tire size

Tire press

2490 cap when load center is 20” from backrest 2190 cap when load center

is 30” from backrest

Important!Important!

The higher the lift, The higher the lift, the lower the capacitythe lower the capacity

Movement of the stability triangleMovement of the stability triangle1. Truck

stopped, no load

2. Truck is loaded or stopped quickly

3. Truck is loaded on right side or turning left

4. Truck is loaded on left

side and/or turning right

5. Truck is loaded and lifting a load with the

mast titled back

Stability Triangle

Key points about the stability triangleKey points about the stability triangle

• If you get outside the stability triangle, the truck If you get outside the stability triangle, the truck could turn overcould turn over

• No quick stops or turnsNo quick stops or turns• Keep load lowKeep load low• Inch slowly when load is lifted for deposit Inch slowly when load is lifted for deposit • Keep loads stable on forks so they don’t shiftKeep loads stable on forks so they don’t shift• Creep when carrying containers of liquidCreep when carrying containers of liquid• Tilt back no more than necessaryTilt back no more than necessary

SURVIVING A TIP-OVERSURVIVING A TIP-OVER• Don’t jumpDon’t jump

• Hold on to steering wheel tightlyHold on to steering wheel tightly

• Brace feet with wide stanceBrace feet with wide stance

• Lean away from the tip directionLean away from the tip direction

REAR-END STEERINGREAR-END STEERING• Due to rear-end steering, Due to rear-end steering,

operators must slow down operators must slow down in order to watch the tail in order to watch the tail swing and the tips of the swing and the tips of the forks at the same time.forks at the same time.

• You can’t do this if your You can’t do this if your driving too fast.driving too fast.

ClarkClark

What’s wrong in this picture?

Load is way to high

Stopped too fast!

Load height is O.K. if stopped to stack, right?

Maybe should be driving backwards

Driver not at the controls

FORKS FORKS (CONT.)(CONT.)

• When a forklift is When a forklift is not in use, the forks not in use, the forks must be grounded must be grounded and leveled.and leveled.

nonoyesyes

FORKS (CONT.)FORKS (CONT.)

• Under no circumstances Under no circumstances should anyone be allowed should anyone be allowed under raised forks, under raised forks, whether loaded or empty.whether loaded or empty.

• This includes fingers & This includes fingers & toes.toes.

ELEVATION OF FORKSELEVATION OF FORKS

• When traveling on level surfaces the forks When traveling on level surfaces the forks should never be raised more than about 4” should never be raised more than about 4” from the floor or ground. from the floor or ground.

• When on unlevel surfaces, the forks When on unlevel surfaces, the forks should not be raised any higher than should not be raised any higher than necessary to clear the ground.necessary to clear the ground.

TRUCK INSPECTIONSTRUCK INSPECTIONS• Forklifts shall be examined before being placed Forklifts shall be examined before being placed

in servicein service • Trucks must be inspected at the end of each Trucks must be inspected at the end of each

shift when used around-the-clockshift when used around-the-clock• Trucks used intermittently must be inspected at Trucks used intermittently must be inspected at

the beginning of each day that the truck is usedthe beginning of each day that the truck is used• Daily inspections shall be retained for 45 daysDaily inspections shall be retained for 45 days• Monthly inspections shall be retained for at Monthly inspections shall be retained for at

least 13 months.least 13 months.

INSPECTIONS INSPECTIONS (cont.)(cont.)

The inspection must at least include the The inspection must at least include the following :following :

A. Leaks (water, fuel, hydraulic A. Leaks (water, fuel, hydraulic fluid, etc.)fluid, etc.)B. Tire damage and adequate B. Tire damage and adequate inflationinflationC. Faulty operation of controls C. Faulty operation of controls

D. Brake condition (service and emergency D. Brake condition (service and emergency brakes)brakes)

E. Proper steeringE. Proper steeringF. Proper accessory operation (horn, lights, F. Proper accessory operation (horn, lights,

ignition switch, etc.)ignition switch, etc.)G. Proper operation of lift/tilt mechanismsG. Proper operation of lift/tilt mechanisms

INSPECTIONS INSPECTIONS (cont.)(cont.)

H. Defects in forksH. Defects in forksI. Battery chargingI. Battery chargingJ. Fuel connections/gaugesJ. Fuel connections/gaugesK. Battery plug connection (if it’sK. Battery plug connection (if it’s electric)electric)

INSPECTIONS INSPECTIONS (cont.)(cont.)

Checking the oilChecking the oil

Add or Low

fullfull

Operating rangeOperating range

From low to full couldFrom low to full couldbe 1 Qt. to 1 gallonbe 1 Qt. to 1 gallon..Put a little in and checkPut a little in and checklevel. Keep doing that.level. Keep doing that.DO NOT OVERFILLDO NOT OVERFILL

Be on a levelBe on a levelsurface to checksurface to checkthe oil. Like on the oil. Like on a concrete pad ora concrete pad orshop floor.shop floor.

• Any maintenance problems should be Any maintenance problems should be brought to the attention of supervision so brought to the attention of supervision so that appropriate repairs can be made.that appropriate repairs can be made.

INSPECTIONS INSPECTIONS (cont.)(cont.)

• Forklifts in an unsafe Forklifts in an unsafe condition condition should never be should never be used.used.

NATIONAL SAFETY NATIONAL SAFETY COUNCIL SAYS . . .COUNCIL SAYS . . .

• The most serious defect is The most serious defect is BRAKE FAILURE..

DAMAGE TO FORKLIFTDAMAGE TO FORKLIFT• If the forklift is damaged in any way or If the forklift is damaged in any way or

develops any kind of mechanical problem develops any kind of mechanical problem while being used it must be immediately while being used it must be immediately reported to your supervisor. reported to your supervisor.

• Do not park a defective forklift without Do not park a defective forklift without tagging it out & telling your supervisor.tagging it out & telling your supervisor.

OSHA SAYS . . .OSHA SAYS . . .

• Only trained and/or qualified persons Only trained and/or qualified persons should make repairs to forklifts.should make repairs to forklifts.

Operating RulesOperating Rules

FOLLOWING ANOTHER FOLLOWING ANOTHER TRUCKTRUCK

• When one forklift is following another, the When one forklift is following another, the following forklift should maintain a following forklift should maintain a distance of three (3) trucks behind the distance of three (3) trucks behind the first.first.

QUICK STOPS QUICK STOPS

• Although the forklifts can be stopped in a Although the forklifts can be stopped in a short distance, the load cannot stop as fast. short distance, the load cannot stop as fast.

• A quick stop may cause the forklift to A quick stop may cause the forklift to loose the load or tip forward.loose the load or tip forward.

USE OF HORNUSE OF HORN

• The horn should be used to warn The horn should be used to warn pedestrians that you are approaching pedestrians that you are approaching

• The horn should also be sounded upon The horn should also be sounded upon entering a building or rounding a blind entering a building or rounding a blind cornercorner

• Sound the horn and look in direction of Sound the horn and look in direction of travel BEFORE backingtravel BEFORE backing

• It is especially important to sound the horn when It is especially important to sound the horn when entering or leaving buildings where employees entering or leaving buildings where employees may be walking across the path of the forklift.may be walking across the path of the forklift.

• Also, be especially careful when entering a Also, be especially careful when entering a building from outside as your eyes will not be building from outside as your eyes will not be adjusted to the lower light.adjusted to the lower light.

• Horns should never be used to startle fellow Horns should never be used to startle fellow employees.employees.

USE OF HORN (cont.)USE OF HORN (cont.)

UNATTENDED FORKLIFTSUNATTENDED FORKLIFTS

• The definition of an The definition of an unattended forklift unattended forklift is:is:– when you are not when you are not

within clear view of the within clear view of the truck, or truck, or

– when you are more when you are more than twenty five feet than twenty five feet (25) feet away from it.(25) feet away from it.

UNATTENDED FORKLIFT (cont.)UNATTENDED FORKLIFT (cont.)

So. . .If the forklift is unattended, you So. . .If the forklift is unattended, you mustmust

• shut down the engine shut down the engine • fully ground the forks fully ground the forks • neutralized the controlsneutralized the controls• set the emergency brake, and set the emergency brake, and • not parked on an incline (unless not parked on an incline (unless

chocks are used)chocks are used)

UNATTENDED FORKLIFT (cont.)UNATTENDED FORKLIFT (cont.)

• If you get off of the forklift but If you get off of the forklift but do not leave it unattended then do not leave it unattended then you must you must – Lower the forks to the ground, Lower the forks to the ground,

– Neutralize the controls and Neutralize the controls and

– Set the emergency brakeSet the emergency brake

– Chock wheels if on an inclineChock wheels if on an incline

UNDER NO UNDER NO CIRCUMSTANCES. . .CIRCUMSTANCES. . .

• Should a forklift Should a forklift be allowed to lift be allowed to lift any more than its any more than its rated capacity.rated capacity.

STABILITY OF LOAD & STABILITY OF LOAD & TRAVELINGTRAVELING

• Loads should be stable. Remember Loads should be stable. Remember that shop floors have rough places that shop floors have rough places and so does the yard. and so does the yard.

• Loads should be balanced, secure Loads should be balanced, secure and stable so there is no possibility and stable so there is no possibility of loosing the load during transit.of loosing the load during transit.

TRAVELINGTRAVELING

• Keep the load Keep the load against the against the backrest (mast) backrest (mast) as much as as much as possible.possible.

TRAVELING TRAVELING (cont.)(cont.)

• 10% grade is when a slope changes 10 10% grade is when a slope changes 10 feet in height in a 100 feet of distance.feet in height in a 100 feet of distance.

• When going up or down an incline of When going up or down an incline of 10 percent grade or more while loaded, 10 percent grade or more while loaded, keep the load uphill.keep the load uphill.

• In other words, go up the grade in In other words, go up the grade in forward and come down the grade in forward and come down the grade in reverse.reverse.

RAILROAD TRACKSRAILROAD TRACKS

• When crossing railroad tracks, the truck When crossing railroad tracks, the truck should cross the tracks diagonally (at an should cross the tracks diagonally (at an angle).angle).

• No parking within 8 ft. of the center of the No parking within 8 ft. of the center of the RR tracksRR tracks

TRAVELING TRAVELING (cont.)(cont.)

• Whether loaded or unloaded, do not Whether loaded or unloaded, do not run over any avoidable objects such run over any avoidable objects such as beam, pipe, loose items, etc. as as beam, pipe, loose items, etc. as tire damage and possible tipping tire damage and possible tipping may occur.may occur.

• Also, avoid any wet spots on shop Also, avoid any wet spots on shop floors as this will effect braking floors as this will effect braking ability and steering control.ability and steering control.

MANEUVERINGMANEUVERING

• When unable to When unable to see in front of you see in front of you because of a large because of a large load, you should load, you should drive backwards drive backwards or have a spotter.or have a spotter.

PERSONNEL LIFTINGPERSONNEL LIFTING

• Employees should never be allowed Employees should never be allowed to be lifted on the forks to be lifted on the forks unless the unless the proper personnel basket is usedproper personnel basket is used..

• Safety platform must be firmly Safety platform must be firmly secured to the lifting carriage and/or secured to the lifting carriage and/or forks.forks.

• Means shall be provided whereby Means shall be provided whereby personnel on the platform can shut personnel on the platform can shut off power to the truck.off power to the truck.

RIDERSRIDERS

• Under no circumstances Under no circumstances should anyone be on a should anyone be on a forklift except the forklift except the operator (unless a safe operator (unless a safe place is provided) place is provided)

• This is the operator’s This is the operator’s responsibilityresponsibility

OVERHEAD CLEARANCEOVERHEAD CLEARANCE

• Always watch for overhead Always watch for overhead clearance such as piping, clearance such as piping, overhead doors, overhead doors, craneways, etc.craneways, etc.

• Never get any closer to an Never get any closer to an electrical line than 20 feet.electrical line than 20 feet.

TRAVELINGTRAVELING

• Travel should be smooth, Travel should be smooth, slow, cautious and the slow, cautious and the operator operator must always must always look in the direction of look in the direction of

travel travel before before beginning to beginning to movemove..

TRAVELING (cont.)TRAVELING (cont.)

• The mast should be tilted The mast should be tilted slightly back, when slightly back, when possible, while traveling possible, while traveling with a loadwith a load..

TRAVELING (cont.)TRAVELING (cont.)

• Forklifts must never Forklifts must never be driven up to be driven up to someone standing in someone standing in front of a bench or front of a bench or other fixed object.other fixed object.

OPERATINGOPERATING

• Arms and legs should Arms and legs should never be outside the never be outside the confines of the confines of the forklift cab or forklift cab or operators position.operators position.

OPERATING (cont.)OPERATING (cont.)

• Never pass another Never pass another forklift going in the same forklift going in the same direction while in the direction while in the shops.shops.

• Pedestrians always have Pedestrians always have the right of way.the right of way.

MANEUVERING & STACKINGMANEUVERING & STACKING

• Do not combine Do not combine turning, turning, raising/lowering raising/lowering forks and depositing forks and depositing load all at one time.load all at one time.

• The procedure The procedure should be as follows:should be as follows:

MANEUVERING & MANEUVERING & STACKING STACKING (cont.)(cont.)

1. Drive up to the place 1. Drive up to the place you intend to deposit or you intend to deposit or pick up load and stop.pick up load and stop.

2. Raise or lower forks 2. Raise or lower forks and tilt forward or and tilt forward or back to deposit or pick back to deposit or pick up load.up load.

MANEUVERING & MANEUVERING & STACKING STACKING (cont.)(cont.)

3. Creep forward and deposit 3. Creep forward and deposit or pick up load.or pick up load.

4. Adjust forks and tilt.4. Adjust forks and tilt.

5. Look to direction of travel.5. Look to direction of travel.

6. Slowly begin travel.6. Slowly begin travel.

DAMAGE REPORTINGDAMAGE REPORTING

• While handling material, report any While handling material, report any damage to the material immediately damage to the material immediately to your supervisor.to your supervisor.

• The damaged material may take The damaged material may take time to replace and the quicker the time to replace and the quicker the damage is reported, the quicker it damage is reported, the quicker it can be fixed or re-ordered.can be fixed or re-ordered.

DAMAGE REPORTING (cont.)DAMAGE REPORTING (cont.)

• Report any damage to property Report any damage to property immediately. This includes damage immediately. This includes damage – To doors,To doors,– Buildings,Buildings,– Structures,Structures,– The forktruck, or The forktruck, or – Other equipment, etc.Other equipment, etc.

HANDLING VESSELSHANDLING VESSELS• Name plates on bottles & scrubbers - do not Name plates on bottles & scrubbers - do not

allow them to be damaged.allow them to be damaged.• Screwed fittings - do not allow the bottle to Screwed fittings - do not allow the bottle to

rest on these fittings or let the bottle roll rest on these fittings or let the bottle roll over on these fittingsover on these fittings

• Use caution so that flange faces are not Use caution so that flange faces are not damageddamaged

• To accomplish this, the bottles may have to To accomplish this, the bottles may have to be suspended under the forks using chokers be suspended under the forks using chokers rather than sitting on the forks.rather than sitting on the forks.

• It is the operator’s It is the operator’s responsibility to figure responsibility to figure out how to avoid out how to avoid damage to these damage to these vessels or any other vessels or any other load.load.

HANDLING VESSELS (cont.)HANDLING VESSELS (cont.)

REFUELINGREFUELING

• During refueling the engine must be During refueling the engine must be shut down.shut down.

• Forklift must be parked away from Forklift must be parked away from any hot work or heat producing any hot work or heat producing operations.operations.

• No smoking.No smoking.

• If propane fuel is used, return empty If propane fuel is used, return empty tank to the proper place.tank to the proper place.

PropanePropane

Relief valve must be pointed UP

Line up holes with peg

WHEN PARKINGWHEN PARKING

• When parking the forklift be sure it When parking the forklift be sure it is not blockingis not blocking– Aisles, Aisles, – Fire extinguishers, Fire extinguishers, – Electrical panels , or Electrical panels , or – Exit doors.Exit doors.

WHEN PARKING (cont.)WHEN PARKING (cont.)• Shut the engine down,Shut the engine down,• Set the handbrake, Set the handbrake, • Ground and level Ground and level

forks, forks, • Neutralize controls, Neutralize controls,

and and • Chock wheels if on an Chock wheels if on an

incline.incline.

MOUNTING AND DISMOUNTINGMOUNTING AND DISMOUNTING

• Do not “jump” off the forkliftDo not “jump” off the forklift

• Use handrails and take your time Use handrails and take your time (maintain 3-point contact at all times)(maintain 3-point contact at all times)

• If the anti-skid surfaces get worn down - If the anti-skid surfaces get worn down - anti-skid tape can be put on them.anti-skid tape can be put on them.

FINALLY . . .FINALLY . . .

• Take care of the machineTake care of the machine

• Don't overloadDon't overload

• Report damageReport damage

• Operate at a safe speedOperate at a safe speed

• Obey all the rulesObey all the rules

QUIZQUIZ