Lift Truck Operator Training Program by HBAA

Alabama Homebuilders Self Insurers Fund

Lift Truck Operator Training Program

Presented by the AHBSIF Loss Control Department

Course Outline

I. Introduction

II. Lift Truck Basics

III. Fuels and Batteries

IV. Emergency Situations

V. Fundamentals of Operation

VI. Driving Test

I. Introduction

This presentation will provide participants with the following:– The importance of lift truck safety– Component, weight, stability, and speed

characteristics of lift trucks– Safe handling of fuels and batteries– Daily maintenance and safety check

procedures

II. Lift Truck BasicsSection 1 - Awareness

Recognition of emphasized messages:

– NOTE• This message is used when special information,

instructions, or identification is required relating to procedures, equipment, tools, pressures, capacities, and other special data.

– IMPORTANT• This 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.

– CAUTION• This message is for proper precautions which, if

not followed, can result in personal injury.– WARNING

• This message is used when a hazard exists which can result in injury or death if proper precautions are not taken.

– DANGER• This 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 others The operator learns how to perform a pre-shift inspection

– Reduce down time and maintenance costs– Increase productivity– Improve safety

The equipment is better cared for– Employees understand the value of the equipment and how to

use it efficiently Operator training and progress is documented OSHA requirements are fulfilled

Forklift Types

Narrow Aisle

Picker

Electric Standup

Forklift Types

Powered Pallet Truck Sit Down Rider

(Pneumatic Tire)

• Section 2 – Components and Stability

Components of a Lift Truck

Overhead GuardUpright

Operator Restraint System

Counterweight

Steer Axle and Wheels Drive Axle and

Wheels

Lift Cylinder

Tilt Cylinder

BackrestFuel Tank

Carriage

Data Plate

• The data plate must be in legible condition

• A data plate provides the following information:– Maximum lift height– Attachment capacities– Maximum weight

capacities

Lift Truck Weight

• Listed capacities are not good indicators of the machines total weight

• A lift truck can weigh two to three times as much as the lifted capacity

• A lift truck usually weighs twice its capacity2:1 ratio

Component Estimated lbs

Truck Weight 8,000 lbs

Capacity 4,000 lbs

Operator 175 lbs

Total 12,175 lbs

Load Center

The 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”

Stability

Even 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 Gravity

As the CG gets higher, the stability of the lift truck gets smaller.

Loads must be kept as low as possible at all times.

Zone 3

Zone 2

Zone 1

Stability

Lif

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• Section 3 – Safety Equipment

Common Safety Devices Roll Over Protection System (ROPS)

– Designed to minimize complete overturn– Employees should never jump from a machine during overturn– Integral Components include:

• Overhead Protection• Seatbelt• Protective cage

Pedestrian Warning Devices– Lights

• Headlights, Brake Lights• Amber Strobes

– Horn and Back-Up Alarm Operator’s 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 & Storage

A 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 Removal

Wear proper personal protective equipment. Do not smoke. Purge the fuel line by closing the tank’s 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 Installation

Select 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 Installation

Reconnect 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 Diesel

The difference between these two fuels is their ignition temperatures.

Gasoline– Extremely flammable– Colorless– Distinctive odor

Diesel– Has higher ignition point than gas– Colorless– Slight odor, harder to detect than gas

Gas and Diesel Refueling

Most 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 Refueling

Safe refueling checklist:– Refuel in designated areas with good

ventilation– Smoking and open flames are prohibited– Shut off the truck, lower the forks, put the

truck in neutral, and set the parking brake before beginning

– Don’t overfill the tank– Clean up any spills– Use only clean, properly marked fuel cans

Batteries

A 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 Hazards

Sulfuric 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 Chargers

Two 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 Charging

Battery recharging requires a special service area in accordance with OSHA section (g)(1). The area must be:– Well ventilated– Truck off, set parking brake– Jewelry is prohibited– Personal protective equipment should include safety

glasses, head protection, aprons, and gloves– All battery cables should be disconnected before

charger hook-up– Handling must be done according to manufacturers

recommendations

Battery Charging

– Vent 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 Emergency

The three C’s, 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 assistance

Care - 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 paper

Flammable Liquids

Includes fuels, grease, other liquids

Electrical Fires

Contains non-conductive smothering agent

How to Use a Fire ExtinguisherP-A-S-S

Pull -- Pull the pin at the top of the extinguisher that keeps the handle from being activated

Aim -- Aim the nozzle at the base of the fire

Squeeze -- 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 Operation

Trained Operators Only– OSHA requires that only trained operators be allowed

to operate fork trucks Stunt Driving and Horseplay is Strictly Prohibited

– Fork trucks are heavy and powerful machines that demand an operators attention and respect

Read and Understand Operator Instructions– You must read and understand the operators manual

for each truck you operate Faulty Equipment and Maintenance

– If 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 Personnel

Operators 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 Personnel

Never 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 Safety

Never 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 Truck

OSHA 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 Truck

Apply 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 Elevators

Lift trucks are not designed to lift people.There are machines designed for this

purpose;– Scissor lifts– Order Pickers (platform lift)– Elevated work platforms

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

Personnel Elevators

Must be designed by a professional engineer

Must be designed to work with a specific lift

Occupants must wear a harness and lanyard

Operators must man controls at all times

Lift Truck Tip Over

In 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 Loads

Always 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 Loads

When 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.

Stacking Square the truck to the

rack/bin and come to a complete stop

Elevate 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.

Traveling Understand the traffic

laws of your environment Familiarize yourself with

the work area.- Visibility- Travel surface

Maintain at least a three truck length distance between yourself and any truck ahead.

Always yield the right-of-way to any emergency vehicle

Traveling Grades, Ramps, and

Inclines– Travel 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.

Traveling

Dock Operations– Before 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 Section

• Pre-operation Inspection

• Familiarization with operating controls and gauges

• Driving exercises– Figure 8 Test– Reverse Mobility– Lifting and Carrying

Pre-Operational ChecklistItem Ok repair Item Ok repair

Forks, 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 Level Hydraulic Controls & Lift

Engine Oil Level All Brakes

Radiator Water Level (Cold)

Steering