Forklift Safety Refresher Training

Today’s Goals

Improve knowledge of safe, professional and efficient operation of forklifts.

Safety review for all operators. Load composition

Benefits Of Forklift Safety Training

Create awareness of safety features and rules. Improve operator and pedestrian safety. Prevention of forklift injuries and deaths. Prevent damage (building, products, forklifts)

Assist in satisfying OSHA requirements.

What Is Management’s Role in Safety?

Comply with the law. Provide a safe work environment. Protect employees and visitors. Provide safe equipment and proper training. Review accidents and near misses. Don’t sacrifice safety under any circumstance.

Follow safe work practices. Protect yourself and your coworkers. Know your fork lift capability Know the load composition-weight & load

center Use all safeguards and safety equipment. Report all accidents and near misses. Take safety seriously, even on common jobs.

What Each Operators Role in Fork lift Safety?

OSHA Requires:

1) All employers furnish their employees a place of employment which is free from recognized hazards.

2) All employees comply with the standards, rules, regulations and orders which are applicable to their own actions and conduct.

What does this mean?

Employers must do everything they can to provide safe workplaces, but employees are required by law to follow all safety rules.

Why do smart people sometimes do stupid things?

In a hurry or under pressure?

Wrong tool for the job?

Lack of focus?

Over confident?

Your Eyes And Mind Must Be Focused When Operating A Forklift

Focus Problems: Boring or repetitious work Operator fatigue Rushing to get the job done Medication or sickness Distractions from other operators, pedestrians, inventory

management systems, phones & radios.

Lack of attention is a major factor in forklift accidents

Know Your Abilities and Limits

ExpertNovice

Functional Advanced

Average

Great skills levels can take many years to develop, be patient and you’ll get there,

know your limits!

80% is required on the quiz.

This Course Was Designed To Protect You And Your Co-workers

Read The Operator’s Manual!

It is your responsibility to read the operator’s manual before operating any forklift. Contact your supervisor if the manual is missing or if you have questions about the features or safe operation of any forklift you are asked to operate.

Attachment Safety Do not operate any attachment until you have been trained to use

it. Read the attachment operator’s manual, if there is one. Know how the attachment affects your forklift’s stability. Treat trucks with attachments as being partially loaded. Inspect the attachment and never use one that is broken,

damaged or missing parts. Keep attachments (and your load) centered whenever possible. Include the weight of all attachments into your load calculation

( Fork adapter, Lifting beam, ect…)

Attachments

Data Plate

Never exceed the capacity or limitations of your forklifts.

Follow safe traveling and lifting practices at all times.

How might this accident have occurred?

Don’t Push The Limits

Data Plate Information

B = Horizontal (out) Load Center and Vertical (up) Load Center

C = Lateral (side to side) Load Center (Units equipped with side shift)

A = Maximum Fork Height

NOTE:

All

distances

will be

listed

in inches

What is the weight of the truck?

Data Plate Exercises

What is the maximum fork height?

Data Plate Exercises

What is the maximum capacity of the truck with forks?

Data Plate Exercises

What is the maximum capacity of the truck with a side shift attachment?

Data Plate Exercises

What is the truck’s horizontal (out) load center?

Data Plate Exercises

What is the truck’s vertical (up) load center?

Data Plate Exercises

What is the maximum height you may safely raise a 2,750 lb. load if the truck is equipped with a side shifter & forks?

Data Plate Exercises

Your truck is equipped with a side shifter & forks. To what height may you safely lift a load of 4,000 lbs?

You can’t safely lift it to any height, the max capacity with side shift and forks is 3,700 lbs

Data Plate Exercises

Know your Capacity

What is the capacity of this fork lift and its rated horizontal load center?

1

2

Know your Capacity

1

2Capacity=7700 lbsRated Load Center=

24”

Know your Capacity & Load Composition

1

2Capacity=7700 lbsRated Load Center=

24”

Does this mean, I can pick up 7700 lbs in any type of configuration or any way I want?

NO!!!!

Know your Capacity & Load Composition

72 inches

The forklift has a capacity of 7700 lbs with a 24 inch load center. That means the forklift is rated to pick up a max of 7700 lbs if the center of the load is at 24 inches.

As the center of the load moves further out the capacity of the forklift decreases.

The actual Load center for this lift is 72 inches-as shown below.

The new calculated capacity of this lift is now de-rated to 33% of its original capacity and now can only lift 2,541 lbs safely.

The lifting operation carried out was 3038 lbs over capacity.

Load characteristics;Engine weight (T\R & Nose Cowl installed): 4,850 lbsLifting beam weight: 320 lbsFork adapter weight: 409 lbsTotal weight of Load= 5,579 lbs

Know your Capacity & Load Composition

Change in Load center effects the capacity of the fork lift!

Good

Bad

Safe Load Capacity

Change in Load center effects the capacity of the fork lift!

.

•Improperly distributed loads may tip the forklift if the operator exceeds the stated capacity of the truck.

•This forklift can carry 4,000 pounds at a 24 inches load center,

• but only 2,666 pounds at a 36 inches load center.

• Requirement- know the safe load capacity of your fork lift.

•Use the “Take 2” methodology- Take a few minutes to ensure your fork lift is capable of safely lifting your load.

Field Calculation of Safe Load Capacity

• Assume a situation where a forklift truck that has a 5,000 pound capacity at a 24 inch load center needs to handle a load whose center is 28 inches from the front face of the forks in the horizontal direction. The first thing to recognize is that the actual load center distance of 28 inches exceeds the standard load center distance of 24 inches on which the 5000 pound capacity is based, so the safe load capacity is actually less than 5000 pounds.

• To estimate the truck's safe load capacity at a 28-inch load center, take the rated load center and divide it by the actual load center. Then multiply this number by the stated capacity to get the new approximate safe load capacity:

24 in/28 in x 5,000 lb = 4,285 lb (approximate safe load capacity)

28 in

5000 lbs

Moving the load center by 2

inches takes the forklift out of

capacity

Field Calculation of Safe Load Capacity

Using the example in above, take the stated standard load center of 24 inches and divide it by the actual load center of 36 inches. Multiply this number by the stated capacity of 4,000 lb to get the new approximate safe load capacity:

24 in/36 in x 4,000 lb = 2,666 (approximate safe load capacity)

TAKE 2!

Prior to any lift, use the “Take 2” methodology-Take a few minutes and carry out the field calculation to determine if your fork lift is capable of safely lifting the load.

Test10 Questions70% to Pass

Question 1This forklift with a 5,000 capacity at a 24” load center can safely move forward and pick up this load?

A)True

B) False

60”

30”

5,000 lbs

Question 2What is the actual horizontal load center?

Question 3Using the information below and the field calculation for safe load capacity, determine the following:

The forklift has a rated capacity of 7700 lbs at a 24 inch load center. If the center of the actual load is 30 inches. What is the new rated safe capacity of the fork lift?

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

A) 7700 lbs

B) B) 6016

C) C) 6160

D) D) 7100

Question 4Using the information below and the field calculation for safe load capacity, determine if this is a safe lift and the fork lift has the capacity to carry out the lift in the given configuration:

ForkliftRated capacity: 12,000 lbs @ 24” load centerFork Hook adapter: Hook is 72” from the front face of the forks

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

72 inches

Load CharacteristicsEngine weight (T\R & Nose Cowl installed):4,850 lbsLifting beam weight: 320 lbsFork adapter weight: 409 lbs

What is the new rated safe capacity of Fork lift?

A) 12,000 lbs

B) 10,240 lbs

C) 6,240 lbs

D) 4,000 lbs

Question 5Using the information below and the field calculation for safe load capacity, determine if this is a safe lift and the fork lift has the capacity to carry out the lift in the given configuration:

ForkliftRated capacity: 12,000 lbs @ 24” load centerFork Hook adapter: Hook is 72” from the front face of the forks

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

72 inches

Load CharacteristicsEngine weight (T\R & Nose Cowl installed):4,850 lbsLifting beam weight: 320 lbsFork adapter weight: 409 lbs

This fork lift is capable to safely lift this load in this configuration.

A) True

B) False

C) True, if this is the only fork lift available

Question 6Using the information below and the field calculation for safe load capacity, determine if this is a safe lift and the fork lift has the capacity to carry out the lift in the given configuration:

Forklift

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

72 inches

Load CharacteristicsEngine & stand weight: 3,050 lbs

What is the new rated safe capacity of Fork lift-up to a height of 134.3 inches?

A) 17,450 lbs

B) 7,920 lbs

C) 9,307 lbs

D) 3,049 lbs

45”

Question 7Using the information below and the field calculation for safe load capacity, determine if this is a safe lift and the fork lift has the capacity to carry out the lift in the given configuration:

Forklift

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

72 inches

Load CharacteristicsEngine & stand weight: 3,050 lbsForks are engaged 2/3 of the way through the load

This fork lift is capable to safely lift this load in this configuration.

A) True

B) False

45”

Question 8Using the information below and the field calculation for safe load capacity, determine if this is a safe lift and the fork lift has the capacity to carry out the lift in the given configuration:

ForkliftRated capacity:9,200 lbs @ 24” load center

Field Calculation

RATED LOAD CENTER

ACTUAL LOAD CENTERRATED CAPACITY = NEW RATED SAFE CAPACITY

72 inches

Load CharacteristicsEngine & stand weight: 3,050 lbsForks are fully engaged into the front fork pockets.

60”

What is the new rated safe capacity of Fork lift?

A) 3,680 lbs

B) 9,000 lbs

C) 6,250 lbs

D) 9,200 lbs

Question 9

72 inches

Prior to lifting a load with a fork lift, what characteristics must be known to determine a safe lift?

A) Weight of the load and capacity of the fork lift

B) Safe Capacity of the forks, diagonal dimension of the load and weight

C) Rated Capacity of the fork lift, rated load center, weight of the load and actual load center

D) Safe Capacity of the fork lift, rated load center and safe CG

Question 10

72 inches

What should a Fork Lift Operator do if she\he determines the fork lift is not capable of lifting the load ?

A) Recalculate using the field calculation and determine the needed weight to add to the back of the fork lift. Install the extra weight using any means necessary to get the job done.

B) Stop, do not carry out the lift operation and inform your Supervisor.

C) Make sure the spotters are in place and lift the load slowly and check to see if the fork lift can handle the load. If so, carry out the lifting operation.

D) Ask other fork lift operators if they have accomplished the same lifting operation in the same configuration. If they have, ask them for advice and carry out the lift using their advice.

Thanks for Your Time and Attention!

Be Safe!