Alabama Homebuilders Self Insurers FundLift Truck Operator Training Program

Presented by the AHBSIF Loss Control Department

Course OutlineIntroductionLift Truck BasicsFuels and BatteriesEmergency SituationsFundamentals of OperationDriving Test

I. Introduction

This presentation will provide participants with the following:The importance of lift truck safetyComponent, weight, stability, and speed characteristics of lift trucksSafe handling of fuels and batteriesDaily maintenance and safety check procedures

II. Lift Truck BasicsSection 1 - Awareness

Recognition of emphasized messages:

NOTEThis message is used when special information, instructions, or identification is required relating to procedures, equipment, tools, pressures, capacities, and other special data.IMPORTANTThis message is used when special precautions should be taken to ensure a correct action or to avoid damage to, or malfunction of, the truck or a component.CAUTIONThis message is for proper precautions which, if not followed, can result in personal injury.WARNINGThis message is used when a hazard exists which can result in injury or death if proper precautions are not taken.DANGERThis message is used when an extreme hazard exists which will result in death or serious injury if proper precautions are not taken immediately.

Benefits of Operator Training

Improved safety for the operator and othersThe operator learns how to perform a pre-shift inspectionReduce down time and maintenance costsIncrease productivityImprove safety

The equipment is better cared forEmployees understand the value of the equipment and how to use it efficiently

Operator training and progress is documentedOSHA requirements are fulfilled

Forklift Types

Narrow Aisle PickerElectric Standup

Forklift Types

Powered Pallet TruckSit Down Rider(Pneumatic Tire)

Section 2 Components and Stability

Components of a Lift TruckOverhead GuardUprightOperator Restraint SystemCounterweightSteer Axle and WheelsDrive Axle and WheelsLift CylinderTilt CylinderBackrestFuel TankCarriage

Data PlateThe data plate must be in legible conditionA data plate provides the following information:Maximum lift heightAttachment capacitiesMaximum weight capacities

Lift Truck WeightListed capacities are not good indicators of the machines total weightA lift truck can weigh two to three times as much as the lifted capacityA lift truck usually weighs twice its capacity

2:1 ratio

ComponentEstimated lbsTruck Weight8,000 lbsCapacity4,000 lbsOperator175 lbsTotal12,175 lbs

Load CenterThe load center rating of a fork truck is the maximum distance from the face of the forks to the center of gravity of a capacity load.

The data plate will have this information.

Standard forks measure 24 at the load center.

For every inch beyond the rated load center that the load is placed, approximately 100 lbs. of capacity is lost.

Load Center

24

StabilityEven though a forklift has four wheels, it is only supported at three points.

The steering axle of most four-wheel lift trucks is attached by means of a pivot point in the center of the axle.

Center of Gravity

The black spot in the triangle below represents the Center of Gravity.The Center of Gravity (CG) shifts according to the movements of the truck.If the CG moves outside the triangle the truck will overturn.

Figure 1 shows the CG shift when the truck is loaded and braking.

Figure 2 shows the CG shift when the truck is uneven or turning with excessive speed.Center of Gravity

Center of GravityAs the CG gets higher, the stability of the lift truck gets smaller. Loads must be kept as low as possible at all times.StabilityLift Height

Section 3 Safety Equipment

Common Safety DevicesRoll Over Protection System (ROPS)Designed to minimize complete overturnEmployees should never jump from a machine during overturnIntegral Components include:Overhead ProtectionSeatbeltProtective cage

Pedestrian Warning DevicesLightsHeadlights, Brake LightsAmber StrobesHorn and Back-Up Alarm

Operators Manual Includes safe operating procedures and capacities

III. Fuels and Batteries

Liquefied Petroleum Gas (LPG)Burns cleaner than gas engines.Produces a poisonous gas that is not easily detectable, must be operated in well ventilated areas.LPG is heavier than air and will seek low lying areas.LPG is extremely flammable, must avoid all sources of ignition

Liquefied Petroleum Gas (LPG)It acts like a liquid. It can soak into clothing.It is compressed under high pressure in the tank.LPG in liquid state has a temperature of 44 below zero. Can cause frostbite on contact with skin.Chemicals are added to give the gas an odor which helps identify leaks.

LPG Tank Handling & StorageA specified area should be designated for the storage and changing of LPG tanks.Tanks should always be stored in their upright position with all gauges and valves at the top whether empty or full.When trucks are parked overnight or for extended periods, the service valve of the tank must be closed.Never park a truck near a source of heat.Always wear proper safety equipment when handling tanks (safety glasses, heavy rubber gloves).

LPG Tank RemovalWear proper personal protective equipment.Do not smoke.Purge the fuel line by closing the tanks service valve and waiting for the engine to run out of fuel. (Controls in neutral, forks down, brake on, ignition off.)Once the service valve is closed, unscrew the line connection and move the hose out of the way.Carefully remove the tank from the mounting bracket.

LPG Tank InstallationSelect a replacement tank in good service condition.Do not roll or drag the new tank to the machine. Use a cart or other suitable equipment.Position the tank in the mounting bracket by aligning the collar hole over the mounting bracket pin. (this is important for fuel consumption and safety)Check all rubber seals in the tank and fuel line connection.

LPG Tank InstallationReconnect the fuel line connection until tight. Slowly turn on the service valve to full and slightly backseat.Make sure both tank clamps are adjusted properly and hold the tank firmly.If no leaks are detected, start the truck and check for normal operation.

Compressed Natural Gas (CNG)The same natural gas that powers hot water heaters and furnaces.CNG is different than LPG in that it remains a gas even under high pressure.CNG is lighter than air and dissipates rapidly when released.CNG tanks are usually permanently mounted to the lift truck.

Gasoline and DieselThe difference between these two fuels is their ignition temperatures.GasolineExtremely flammableColorlessDistinctive odor

DieselHas higher ignition point than gasColorlessSlight odor, harder to detect than gas

Gas and Diesel RefuelingMost lift trucks filler caps are equipped with a venting device and a fuel screen.The screen serves as a fire retardant device by keeping fire out of the fuel tank.Check when refueling to make sure the screen is in place.

Gas and Diesel RefuelingSafe refueling checklist:Refuel in designated areas with good ventilationSmoking and open flames are prohibitedShut off the truck, lower the forks, put the truck in neutral, and set the parking brake before beginningDont overfill the tankClean up any spillsUse only clean, properly marked fuel cans

BatteriesA lead-acid battery is a portable power source for supplying direct current electricity.The most common voltages include 12, 24, 36, and 48 volts.Discharging a battery below 80% of its total capacity can result in shortened battery and truck component life.

Battery HazardsSulfuric Acid Small amounts can cause severe contact burns to the skin.Gasses Batteries produce hydrogen and oxygen mixture continuously. Keep all ignition sources away.Electricity Batteries are capable of producing very high discharge rates. Avoid direct shorting situations.Battery Weight Use care when handling, charging, and using batteries in the truck.

Battery ChargersTwo types:Single Phase charger has two wires and a ground with one transformer and two fuses.Three Phase charger has three wires and a ground in the power supply cable. It has three transformers and three fuses.

Always correctly match the charger to the voltage and amp hour ratings of the battery.Also check the input voltage and cycle. Input voltage is most commonly 220, 440, or 480, with US Standard 60 cycles.

Battery ChargingBattery recharging requires a special service area in accordance with OSHA section (g)(1). The area must be:Well ventilatedTruck off, set parking brakeJewelry is prohibitedPersonal protective equipment should include safety glasses, head protection, aprons, and glovesAll battery cables should be disconnected before charger hook-upHandling must be done according to manufacturers recommendations

Battery ChargingVent caps must be left on during charging.If the battery is charged while still in the truck, the compartment must be left open.The charger should be turned off before it is connected to the battery then turned on to begin the charging cycle.Color coded connectors help prevent connecting a battery of the wrong voltage to the wrong charger or truck.Chargers should be properly set to avoid over or under charging.The charger should be turned off before disconnecting from the battery.

IV. Emergency Situations

Are you prepared?Does the facility have an evacuation procedure?Are emergency contact numbers readily available?Do any of your employees/co-workers have CPR or First Aid training?Does the facility have a first aid kit?

Handling an EmergencyThe three Cs, Check, Call, Care help us remember what to do in an emergency situation.

Check check the area for your own safety first, then the victim's Call for help, 911 or whom ever is in the immediate area that can provide assistanceCare - administer care to the victim, this may be first aid or at least stabilization

Fire Prevention - Extinguishers

Ordinary Combustibles Includes materials such as wood and paperFlammable LiquidsIncludes fuels, grease, other liquids Electrical FiresContains non-conductive smothering agent

How to Use a Fire ExtinguisherP-A-S-SPull -- Pull the pin at the top of the extinguisher that keeps the handle from being activatedAim -- Aim the nozzle at the base of the fireSqueeze -- Maintain a distance of eight to ten feet away from the fire and squeeze the handle. Discharge will only occur if the handle is being squeezed.Sweep -- Sweep the nozzle back and forth at the base of the fire until it appears to be out.

V. Fundamentals of Operation

Safe Truck OperationTrained Operators OnlyOSHA requires that only trained operators be allowed to operate fork trucks

Stunt Driving and Horseplay is Strictly ProhibitedFork trucks are heavy and powerful machines that demand an operators attention and respect

Read and Understand Operator InstructionsYou must read and understand the operators manual for each truck you operate

Faulty Equipment and MaintenanceIf at any time the fork truck is in need of repair or defective in any way, it must be taken out of service and fixed

Operating Around PersonnelOperators should not rely on pedestrian warning devices and mirrors. Know the terrain and visibility of your workplace.Sound your horn at intersections and blind spots.If your view is blocked because of the load, travel backwards. If you must move forward, make sure that people are out of the way and move the lift truck slowly.

Operating Around PersonnelNever attempt to move a load that requires someone to steady or position the material.Restack the load and/orSecure the load to a pallet.Never drive the fork truck up to someone in front of a fixed object. Avoid potential caught between exposures.

Upright and Fork SafetyNever allow anyone to walk under raised upright whether loaded or empty.Never allow anyone to stand on the forks or climb the upright assembly.Never allow anyone to reach or to step in the areas of the mast, carriage, forks, or load.Never allow anyone to ride on the truck.

Leaving or Parking the TruckOSHA considers a fork truck unattended if the operator is 25 feet away or out of sight of the truck. Use the following tips when leaving the truck or parking it for long periods:

Bring the machine to a complete stop.Turn off the engine, for LPG trucks, shut off the service valve and let the engine run out of fuel.Lower all attachments completely. Put the forks on the floor.Place all controls in neutral.

Leaving or Parking the TruckApply the parking brake.Never park on a grade or around traffic.Never leave the truck parked on a dock ramp, dock leveler, or in a trailer.Never park the truck where it blocks emergency or fire-fighting equipment or emergency travel routes.Chock the wheels if needed.Turn off power supply and remove the keys if possible.

Personnel ElevatorsLift trucks are not designed to lift people.There are machines designed for this purpose;Scissor liftsOrder Pickers (platform lift)Elevated work platforms

OSHA does allow the practice under specific conditions (ASME B56.1).

Personnel ElevatorsMust be designed by a professional engineerMust be designed to work with a specific liftOccupants must wear a harness and lanyardOperators must man controls at all times

Lift Truck Tip OverIn case of a tip-over, use the following precautions:Wear your seatbelt.Never attempt to leap from the truck.Grip the wheel firmly with both hands.Brace your feet firmly against the floor boards.

Handling LoadsAlways balance and secure the load.Never pick loads that are too heavy.Be aware of your clearances at all times. Check for overhead obstructions or power lines.Center the load. Forks must be at least 2/3 the length of the load.

Handling Loads

2/3 Length

Handling LoadsWhen picking up a load, place the forks under the load as far as possible.Tilt the mast back slightly for stabilization.Keep the load low. The forks should never be more than 6 to 8 inches from the ground.

StackingSquare the truck to the rack/bin and come to a complete stopElevate the load to the proper height and Inch the truck in Tilt the load forward for placement.Lower the forks to take pressure off the pallet.Back the truck up till the forks clear and lower them before traveling.Use the same procedure in reverse when picking up a load from a stack.

TravelingUnderstand the traffic laws of your environmentFamiliarize yourself with the work area.- Visibility- Travel surfaceMaintain at least a three truck length distance between yourself and any truck ahead.Always yield the right-of-way to any emergency vehicle

TravelingGrades, Ramps, and InclinesTravel must be straight up and straight down. Never turn on ramps, slopes, or inclines.With a load, travel up or down with the load pointing upgrade.Without a load, travel up or down with the forks pointing downgrade.The load should be tilted back and raised only as high as necessary to clear the surface.

TravelingDock OperationsBefore entering a tractor trailer make certain the wheels are chocked.Check the trailer jacks. Make sure they are fully lowered and secured.Inspect the floor of the trailer prior to driving on it.Check the dock boards between the trailer and the dock. Always travel slowly over dock boards.Stay away from the edge of the dock.Use lights to improve visibility while working in trailers.

Hands-On SectionPre-operation InspectionFamiliarization with operating controls and gaugesDriving exercisesFigure 8 TestReverse MobilityLifting and Carrying

Pre-Operational Checklist

ItemOkrepairItemOkrepairForks, Backrest, Carriage Leaks under Fork Lift Mast, Chain, Hydraulic Lines Seat and Seat belts Tires, Axles Horn and/or Backup alarm Overhead Guard/ROPS Lights, Bodywork Fuel Tank & Connections Gauges and Instruments Fuel LevelHydraulic Controls & LiftEngine Oil LevelAll Brakes Radiator Water Level (Cold) Steering