Forklift Operator Qualification Program Training by Reagan Equipment Company


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  • These are the statistics from the OSHA website.
    Notice what the top 4 are.
    Struck by truck
    Struck by falling load
    Elevated employees (this means people being elevated using the forks)
  • Notice the highest fatality incidences are
    Crushed by a tipping truck and crushed between a truck and an object
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  • PHASE 1: This is what we are doing now.
    PHASE 2: This is the practical part of the training which will be completed over the next month or so.
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  • MODIFICATION OR ADDITIONS: This would be for example, adding more counterweight, modifying the roll-over cage or adding an after-market attachment.
    NAME PLATES MUST BE IN PLACE: This is a pain. Most of our older forklifts won’t have these. We need to request them from the manufacturer and retro fit them on our trucks.
  • ATTENTION SHOULD BE PAID: This becomes a problem in the winter time when we close all the doors in the shop.
  • When looking at the nameplate, the capacity shown is usually 24” from the backrest. You need to take into consideration, though, what the center of gravity of what the load is.
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  • In this picture we can see that the capacity is 4,350 pounds with the center of the load at 24” from the backrest. What happens is the center of the load is 4,350 pounds at 30” from the backrest. We are getting too forward in our stability triangle and the rear wheels might lift up and we can’t steer.
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  • Always keep the load as low as possible for maximum stability
  • STABILITY TRIANGLE: Think of circle #1 as a plumb bob dangling from a string. If the plumb bob gets outside of the triangle, the truck becomes unstable and could turn over.
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  • These are recommendations in the event of a tip over.
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  • Let the class tell you what they think is wrong before clicking the mouse. Then discuss each wrong thing with each mouse click.
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  • Admit that this is kind of elementary to have to bring it up, but people will overfill the crankcase and the truck and it will cause slip hazards
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    After reading slide, mention that when report cards are done by regional support coordinators, they will check the horn. If it doesn’t work, they will know that the daily inspection process is being “pencil whipped”
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  • After reading the slide, tell them that this is important because forklifts do roll down hills and run into buildings without a driver in the seat.
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  • WHEN GOING UP OR DOWN AN INCLINE: 10% grade means 10 feet rise or fall for every horizontal 100 feet.
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    Then tell them that a proper basket has all 4 sides guarded with 42 inch railing and midrails, with 4” toeboards, and the basket must be secured so that they can not come off the forks. Also, when someone is in the basket, the operator must stay at the controls of the forklift.
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  • This doesn’t mean start moving backwards and THEN look. It means look before moving.
  • This keeps you more inside the stability triangle.
  • Remember that one of the top 4 injuries was from being struck by a forklift.
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    Give the example of a valve being damaged that has a 4 week lead time. If not reported immediately, it could delay ship date.
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    These are especially important when it’s rainy, muddy and icy conditions.
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  • Administer the quiz
  • Forklift Operator Qualification Program Training by Reagan Equipment Company

    2. 2. Objectives of this course • To become qualified to operate a forklift (aka forktruck or Powered Industrial Truck) • • • • Learn the rules for safe operation How to avoid forktruck accidents How to prevent high maintenance cost Verify your understand of what you learned with a quiz
    3. 3. S T t tru ruc ipo c k k b ver by y t E fa ruc le l li va ng k te lo d em ad Im pl R pr oy op an ee er of m fd o ai nt ck en Tr an uc Lo ce k s st t c ru o ck ntr O m ol ve a rc U om ter nl ia oa e l di by ng F C un aul O ch ty oc tru ke ck d tra Fe ile ll r of Im f tr uc pr k op E le c t er u ro cu se at io ns S Causes of Accidents 30 25 20 15 10 5 0
    4. 4. A cc S id en ta la ct fro m 2 fa ll i ng iva t io n of c on tro ls fo rk s at er ia l on m ov er tru ck ob je ct tru ck or ra n pl at fo rm by by be tw ee n an d t ip pi ng tru ck by tru ck tru ck S C ru sh ed be tw ee n Fa ll C ru sh ed C ru sh ed Causes of Fatalities 45 40 35 30 25 20 15 10 5 0
    5. 5. Qualification Program • This program is not designed to "teach" employees how to operate a forklift. • It is intended only to confirm the safety aspects of forklift operation for those people already familiar with its operation.
    6. 6. Who Can Use A Lift Truck? “Only trained and authorized personnel shall be permitted to operate forklifts.”
    7. 7. Training requirement • Phase 1: Classroom instruction & quiz • Phase 2: Observation of the trainee operating a truck by a person experienced in forklift operation Notes about Phase 2: – training must not endanger the trainee or other employees. – the observation must be completed on each truck the employee will be assigned to operate.
    8. 8. Refresher training is required when . . . • The operator has been observed operating in an unsafe manner • The operator is involved in an incident or nearmiss • The operator is assigned to operate a different type truck • A condition in the workplace changes in a manner that could affect safe operation of the truck. • At least every 3 years.
    9. 9. HIGH ACCIDENT & MAINTENACE COSTS Are usually results of : • Safety rule violations • Near misses • Hot-Dogging • Lack of inspections
    10. 10. General Requirements • Modifications or additions to forklifts must be approved, in writing, by the manufacturer • Name plates must reflect all front-end attachments • Nameplates must be in place and legible
    11. 11. General Requirements (cont.) • Truck shall not be used around flammable vapors or hazardous concentrations of metal dust unless they are designated as a DY, EE, or EX • Attention should be paid to carbon monoxide (CO) levels in work areas where truck are operating
    12. 12. Load Center Load center
    13. 13. MAXIMUM LOAD • There will be several weights stenciled on the nameplate. • The weights listed will be with the uprights vertical and the center of gravity of the load at various distances from the backrest.
    14. 14. 4350# with load center 24” from backrest 24 4350
    15. 15. Name Plate Tire size 2490 cap when load center is 20” from backrest Capacity 2190 cap when load center is 30” from backrest Load Center Tire press
    16. 16. Important! The higher the lift, the lower the capacity
    17. 17. Movement of the stability triangle 2. Truck is loaded or stopped quickly 1. Truck stopped, no load Stability Triangle 3. Truck is loaded on right side or turning left 5. Truck is loaded and 4. Truck is lifting a load with the loaded on left mast titled back side and/or turning right
    18. 18. Key points about the stability triangle • If you get outside the stability triangle, the truck could turn over • No quick stops or turns • Keep load low • Inch slowly when load is lifted for deposit • Keep loads stable on forks so they don’t shift • Creep when carrying containers of liquid • Tilt back no more than necessary
    19. 19. SURVIVING A TIP-OVER • • • • Don’t jump Hold on to steering wheel tightly Brace feet with wide stance Lean away from the tip direction
    20. 20. REAR-END STEERING • Due to rear-end steering, operators must slow down in order to watch the tail swing and the tips of the forks at the same time. • You can’t do this if your driving too fast.
    21. 21. What’s wrong in this picture? Load is way to high Stopped too fast! Load height is O.K. if stopped to stack, right? Clark Maybe should be driving backwards Driver not at the controls
    22. 22. FORKS (CONT.) • When a forklift is not in use, the forks must be grounded and leveled. yes no
    23. 23. FORKS (CONT.) • Under no circumstances should anyone be allowed under raised forks, whether loaded or empty. • This includes fingers & toes.
    24. 24. ELEVATION OF FORKS • When traveling on level surfaces the forks should never be raised more than about 4” from the floor or ground. • When on unlevel surfaces, the forks should not be raised any higher than necessary to clear the ground.
    25. 25. TRUCK INSPECTIONS • Forklifts shall be examined before being placed in service • Trucks must be inspected at the end of each shift when used around-the-clock • Trucks used intermittently must be inspected at the beginning of each day that the truck is used • Daily inspections shall be retained for 45 days • Monthly inspections shall be retained for at least 13 months.
    26. 26. INSPECTIONS (cont.) The inspection must at least include the following : A. Leaks (water, fuel, hydraulic fluid, etc.) B. Tire damage and adequate inflation C. Faulty operation of controls
    27. 27. INSPECTIONS (cont.) D. Brake condition (service and emergency brakes) E. Proper steering F. Proper accessory operation (horn, lights, ignition switch, etc.) G. Proper operation of lift/tilt mechanisms
    28. 28. INSPECTIONS (cont.) H. Defects in forks I. Battery charging J. Fuel connections/gauges K. Battery plug connection (if it’s electric)
    29. 29. Checking the oil Operating range Add or Low Be on a level surface to check the oil. Like on a concrete pad or shop floor. full From low to full could be 1 Qt. to 1 gallon. Put a little in and check level. Keep doing that. DO NOT OVERFILL
    30. 30. • Any maintenance problems should be brought to the attention of supervision so that appropriate repairs can be made.
    31. 31. INSPECTIONS (cont.) • Forklifts in an unsafe condition should never be used.
    32. 32. NATIONAL SAFETY COUNCIL SAYS . . . • The most serious defect is BRAKE FAILURE.
    33. 33. DAMAGE TO FORKLIFT • If the forklift is damaged in any way or develops any kind of mechanical problem while being used it must be immediately reported to your supervisor. • Do not park a defective forklift without tagging it out & telling your supervisor.
    34. 34. OSHA SAYS . . . • Only trained and/or qualified persons should make repairs to forklifts.
    35. 35. Operating Rules
    36. 36. FOLLOWING ANOTHER TRUCK • When one forklift is following another, the following forklift should maintain a distance of three (3) trucks behind the first.
    37. 37. QUICK STOPS • Although the forklifts can be stopped in a short distance, the load cannot stop as fast. • A quick stop may cause the forklift to loose the load or tip forward.
    38. 38. USE OF HORN • The horn should be used to warn pedestrians that you are approaching • The horn should also be sounded upon entering a building or rounding a blind corner • Sound the horn and look in direction of travel BEFORE backing
    39. 39. USE OF HORN (cont.) • It is especially important to sound the horn when entering or leaving buildings where employees may be walking across the path of the forklift. • Also, be especially careful when entering a building from outside as your eyes will not be adjusted to the lower light. • Horns should never be used to startle fellow employees.
    40. 40. UNATTENDED FORKLIFTS • The definition of an unattended forklift is: – when you are not within clear view of the truck, or – when you are more than twenty five feet (25) feet away from it.
    41. 41. UNATTENDED FORKLIFT (cont.) So. . .If the forklift is unattended, you must • shut down the engine • fully ground the forks • neutralized the controls • set the emergency brake, and • not parked on an incline (unless chocks are used)
    42. 42. UNATTENDED FORKLIFT (cont.) • If you get off of the forklift but do not leave it unattended then you must – Lower the forks to the ground, – Neutralize the controls and – Set the emergency brake – Chock wheels if on an incline
    43. 43. UNDER NO CIRCUMSTANCES. . . • Should a forklift be allowed to lift any more than its rated capacity.
    44. 44. STABILITY OF LOAD & TRAVELING • Loads should be stable. Remember that shop floors have rough places and so does the yard. • Loads should be balanced, secure and stable so there is no possibility of loosing the load during transit.
    45. 45. TRAVELING • Keep the load against the backrest (mast) as much as possible.
    46. 46. TRAVELING (cont.) • 10% grade is when a slope changes 10 feet in height in a 100 feet of distance. • When going up or down an incline of 10 percent grade or more while loaded, keep the load uphill. • In other words, go up the grade in forward and come down the grade in reverse.
    47. 47. RAILROAD TRACKS • When crossing railroad tracks, the truck should cross the tracks diagonally (at an angle). • No parking within 8 ft. of the center of the RR tracks
    48. 48. TRAVELING (cont.) • Whether loaded or unloaded, do not run over any avoidable objects such as beam, pipe, loose items, etc. as tire damage and possible tipping may occur. • Also, avoid any wet spots on shop floors as this will effect braking ability and steering control.
    49. 49. MANEUVERING • When unable to see in front of you because of a large load, you should drive backwards or have a spotter.
    50. 50. PERSONNEL LIFTING • Employees should never be allowed to be lifted on the forks unless the proper personnel basket is used. • Safety platform must be firmly secured to the lifting carriage and/or forks. • Means shall be provided whereby personnel on the platform can shut off power to the truck.
    51. 51. RIDERS • Under no circumstances should anyone be on a forklift except the operator (unless a safe place is provided) • This is the operator’s responsibility
    52. 52. OVERHEAD CLEARANCE • Always watch for overhead clearance such as piping, overhead doors, craneways, etc. • Never get any closer to an electrical line than 20 feet.
    53. 53. TRAVELING • Travel should be smooth, slow, cautious and the operator must always look in the direction of travel before beginning to move.
    54. 54. TRAVELING (cont.) • The mast should be tilted slightly back, when possible, while traveling with a load.
    55. 55. TRAVELING (cont.) • Forklifts must never be driven up to someone standing in front of a bench or other fixed object.
    56. 56. OPERATING • Arms and legs should never be outside the confines of the forklift cab or operators position.
    57. 57. OPERATING (cont.) • Never pass another forklift going in the same direction while in the shops. • Pedestrians always have the right of way.
    58. 58. MANEUVERING & STACKING • Do not combine turning, raising/lowering forks and depositing load all at one time. • The procedure should be as follows:
    59. 59. MANEUVERING & STACKING (cont.) 1. Drive up to the place you intend to deposit or pick up load and stop. 2. Raise or lower forks and tilt forward or back to deposit or pick up load.
    60. 60. MANEUVERING & STACKING (cont.) 3. Creep forward and deposit or pick up load. 4. Adjust forks and tilt. 5. Look to direction of travel. 6. Slowly begin travel.
    61. 61. DAMAGE REPORTING • While handling material, report any damage to the material immediately to your supervisor. • The damaged material may take time to replace and the quicker the damage is reported, the quicker it can be fixed or re-ordered.
    62. 62. DAMAGE REPORTING (cont.) • Report any damage to property immediately. This includes damage – – – – – To doors, Buildings, Structures, The forktruck, or Other equipment, etc.
    63. 63. HANDLING VESSELS • Name plates on bottles & scrubbers - do not allow them to be damaged. • Screwed fittings - do not allow the bottle to rest on these fittings or let the bottle roll over on these fittings • Use caution so that flange faces are not damaged • To accomplish this, the bottles may have to be suspended under the forks using chokers rather than sitting on the forks.
    64. 64. HANDLING VESSELS (cont.) • It is the operator’s responsibility to figure out how to avoid damage to these vessels or any other load.
    65. 65. REFUELING • During refueling the engine must be shut down. • Forklift must be parked away from any hot work or heat producing operations. • No smoking. • If propane fuel is used, return empty tank to the proper place.
    66. 66. Propane Line up holes with peg Relief valve must be pointed UP
    67. 67. WHEN PARKING • When parking the forklift be sure it is not blocking – – – – Aisles, Fire extinguishers, Electrical panels , or Exit doors.
    68. 68. WHEN PARKING (cont.) • • • Shut the engine down, Set the handbrake, Ground and level forks, • Neutralize controls, and • Chock wheels if on an incline.
    69. 69. MOUNTING AND DISMOUNTING • Do not “jump” off the forklift • Use handrails and take your time (maintain 3-point contact at all times) • If the anti-skid surfaces get worn down anti-skid tape can be put on them.
    70. 70. FINALLY . . . • • • • • Take care of the machine Don't overload Report damage Operate at a safe speed Obey all the rules
    71. 71. QUIZ