Price $9.95 Forklift Safety Guidelines Rough Terrain ... Safety...SUNBELT RENTALS Forklift Safety Guidelines '. Types of Forklifts Rough Terrain (RTFL) • Class 7 Powered Industrial

ForkliftSafetyGuidelines

OSHA 1910.178(I):Rough Terrain ForkliftsWarehouse Forklifts

Price $9.95

Sunbelt Rentals Safety Training

1-866-455-4106

Also Available:

Forklift Safety Guidelines: OSHA 1910.178(I), Spanish AWP Safety Guidelines: ANSI A92, English or Spanish

Scaffold Competent Person Training, English or SpanishEarth Moving Safety Guidelines

Excavations, OSHA29 CFR, Part 1926, Subpart P

This log belongs to: __________________________________________________________

Telephone: _____________________________________________________________________

Forklift Safety GuidelinesRough Terrain and Warehouse

In Compliance withOSHA 1910.178(l)

Also Available:

Forklift Safety Guidelines: OSHA 1910.178(I), Spanish AWP Safety Guidelines: ANSI A92, English or Spanish

Scaffold Competent Person Training, English or SpanishEarth Moving Safety Guidelines

Excavations, OSHA29 CFR, Part 1926, Subpart P

SBFSGPG 8-2011R

Equipment Operator Log

Hours ofMake Model Date Operation

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1. Introduction

2. Why Are We Here?

3. Types of Forklifts

4. Familiarization and Delivery

5. Worksite Hazard Assessment

6. Pre-start Inspection

7. Equipment Operation

8. Shut Down

9. Effective Training

Gear Points

Introduction

IntroductionIndemnity—The recipients of, and attendees to, this safety seminar shall indemnify and save Sunbelt Rentals from any and all claims, demands, actions and causes of action against Sunbelt Rentals whether groundless or not, in connection with any and all injuries, losses, damages or liability of any kind whatsoever arising, directly or indirectly, out of the use, distribution or sales of products or services by or through the Recipient or its affiliates whether or not the claims, demands, actions, or causes of action are alleged to have resulted in whole or in part from negligent acts or omissions of Sunbelt Rentals or from acts or omissions of such persons for which they or any of them would otherwise be strictly liable. This indemnification obligation shall include, without limiting the generality of the foregoing, reasonable attorney̕s fees and other costs or expenses incurred in connection with the defense of any and all such claims, demands, actions or causes of actions and shall extend to the trustees, officers, employees, and agents of Sunbelt Rentals.

SUNBELT RENTALS Forklift Safety GuidelinesSUNBELT RENTALS Forklift Safety Guidelines

Sunbelt Rentals hopes that this guide and the subsequent safety seminar will aid you in understanding how to use forklift equipment. It is difficult to cover all areas and to foresee all variances. These aids should be used only as guidelines and in no way do we represent them to you as a complete list of safety rules. There could be special job-related safety requirements omitted from this guide and/or seminar. By not taking them into account, a serious accident, which could cause serious injury or death, could occur to you the employee. Refer to the Operating & Safety Handbook for the machinery you are operating, Occupational Safety & Health Act, ANSI/AMSE standards for Fork Trucks.

Note: Each student must complete this classroom portion and

the hands-on training in order to receive the wallet card

of completion.

Introduction

Introduction

What type of accidents have you witnessed or been involved in?

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

Why are you here?

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

_______________________________________________________________________________

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down


Why Are We Here?

What Are the Real Costs of an Accident?• For every $1 of insured costs

• Uninsured costs $6 to $50

— Property damage

— Equipment & tool damage

— Job delays

— Overtime

— Replacement workers

— Hiring & training

— Investigation time

— Clerical

— Litigation

— OSHA fines

Accidents cost everyone!


U.S. Department of Labor Occupational Safety & Health Administration (OSHA)Occupational Safety and Health Administration or Act writes regulations (www.osha.gov), and polices those regulations with field inspectors who write citations and levy fines.

24 states have their own state programs, but follow the Federal regulations: Alaska, Arizona, California, Connecticut, Hawaii, Indiana, Iowa, Kentucky, Maryland, Michigan, Minnesota, Nevada, New Jersey, New Mexico, New York, North Carolina, Oregon, South Carolina, Tennessee, Utah, Vermont, Virginia, Washington, Wyoming.

Why Are We Here?

Workplace HazardsActivity Part 1: Identify Hazards

Time: 5 minutes

Think about the job site you are currently working on (or most recently worked on). List as many real or potential hazards as you can.

______________________________________

______________________________________

______________________________________

______________________________________

Are You Competent?Activity Part 2: Eliminate Hazards

Time: 5 minutes

Now, for each of your identified hazards, list the corrective action to be taken to eliminate the hazard.

____________________________________

____________________________________

____________________________________

____________________________________

Who is Responsible?Who? What? Why?

_________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ _________________________

Team Name: __________________________________________________________


AgendaWhat are we going to cover in today̕s class?What you need to know to be a safe operator of a:

This includes:

1. ________________________________________________________________________________

2. ________________________________________________________________________________

3. ________________________________________________________________________________

Warehouse Forklift

Rough Terrain Reach Forklift (RTFL)

Rough Terrain Straight Mast Forklift

Why Are We Here?

ASME/ANSI B56.1 and B56.6• ASME – American Society of Mechanical Engineers

• ANSI – American National Standards Institute

— Warehouse type Forklifts B56.1

— Rough Terrain Forklifts B56.6


OSHA 1910.178(l)OSHA requires operator training on forklifts (as of Dec. 1999 this includes construction)

Safe Operation

• The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in this paragraph(l).

• Prior to permitting an employee to operate a powered industrial truck (except for training purposes), the employer shall ensure that each operator has successfully completed the training required by this paragraph(l), except as permitted by paragraph(l)(5).

Training Program Implementation

• Trainees may operate a powered industrial truck only: under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and 1910.178(l)(2)(i)

Why Are We Here?

(B) where such operation does not endanger the trainee or other employees.

• Training shall consist of a combination of formal instruction (e.g., lecture, discussion, interactive computer learning, video tape, written material), practical training (demonstrations performed by the trainer and practical exercises performed by the trainee), and evaluation of the operator̕s performance in the workplace.

• All operator training and evaluation shall be conducted by persons who have the knowledge, training, and experience to train powered industrial truck operators and evaluate their competence.

Training Program Content

• Powered industrial truck operators shall receive initial training in the following topics, except in topics which the employer can demonstrate are not applicable to safe operation of the truck in the employer̕s workplace.

Truck-related topics:

— Operating instructions, warnings, and precautions for the types of truck the operator will be authorized to operate;

— Differences between the truck and the automobile;


— Truck controls and instrumentation: where they are located, what they do, and how they work;

— Engine or motor operation;

— Steering and maneuvering;

— Visibility (including restrictions due to loading);

— Fork and attachment adaptation, operation, and use limitations;

— Vehicle capacity;

— Vehicle stability;

— Any vehicle inspection and maintenance that the operator will be required to perform;

— Refueling and/or charging and recharging of batteries;

— Operating limitations;

— Any other operating instructions, warnings, or precautions listed in the operator̕s manual for the types of vehicle that the employee is being trained to operate.

Workplace-related topics:

— Surface conditions where the vehicle will be operated;

— Composition of loads to be carried and load stability;

— Load manipulation, stacking, and unstacking;

Why Are We Here?

— Pedestrian traffic in areas;

— Narrow aisles and other restricted places;

— Hazardous (classified) locations;

— Ramps and other sloped surfaces that could affect the vehicle̕s stability;

— Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust;

— Other unique or potentially hazardous environmental conditions in the workplace.

Refresher Training and Evaluation

• Refresher training, including an evaluation of the effectiveness of that training, shall be conducted as required by paragraph(l)(4)(ii) to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

• Refresher training in relevant topics shall be provided to the operator when:

— The operator has been observed to operate the vehicle in an unsafe manner;

— The operator has been involved in an accident or near-miss incident;


— The operator has received an evaluation that reveals that the operator is not operating the truck safely;

— The operator is assigned to drive a different type of truck; or

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

• An evaluation of each powered industrial truck operator̕s performance shall be conducted at least once every three years.

• Avoidance of duplicate training

• Previous training that qualifies the operator to operate the assigned truck and the operator has been evaluated on that truck.

Certification

• The employer shall certify that each operator has been trained and evaluated as required by this paragraph(l). The certification shall include the name of the operator, the date of the training, the date of the evaluation, and the identity of the person(s) performing the training or evaluation.

Why Are We Here?

OSHA 1910.178Powered Industrial Trucks

• Forklifts


The Most Serious Accidents➤ Tip over 24%➤ Struck by material 17%➤ Struck by forklift 14%➤ Worker fell from forklift 14%➤ Worker pinned between objects 11%➤ Forklift ran off dock 8%➤ Worker died during forklift repair 6%


What is Missing from Most Forklift Training?

What is a forklift? __________________________________________________________

Stability ________________________________________________________________________

Attachments _________________________________________________________________

Load chart ____________________________________________________________________

Why Are We Here?

The Law of the Lever According to Archimedes…Born 287 B.C.

• “Magnitudes are in equilibrium at distances reciprocally proportional to their weights.”

• “GIVE ME A PLACE TO STAND AND I WILL

MOVE THE EARTH.” A remark of Archimedes quoted by Pappus of Alexandria in his “Collection”


Course Objectives and Goals• To provide the student with:

— An understanding of your responsibilities

— An understanding of a workplace inspection

— An understanding of the various types of forklifts

— An understanding of a pre-start inspection

— An understanding of the hazards involved

— Written exam

— Hands-on training

— How to prevent accidents

Why Are We Here?

Why Are We Here?• Only qualified personnel shall operate the equipment

— Qualified through knowledge, skills and experience and has demonstrated their ability to operate the equipment and recognize hazards associated with the equipment

• Taking class will not make you an operator

— Only hours in the operators seat will accomplish this

• Develop good habits

• Dispel bad habits

• Each machine is different

— Read operator̕s manuals

• Take time to get familiar with the controls


Why Are We Here?

1. Accidents cost ___________________________________________________________

2. We will be addressing the ___________________________________________

standards in this class.

3. Name two of the most common forklift accidents?

________________________________________________________________________________

________________________________________________________________________________

Gear Quizuiz

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down



Types of ForkliftsRough Terrain (RTFL)

• Class 7 Powered Industrial Trucks

• Pneumatic (air) tires

• Intended use

• Rough Terrain, Variable Reach, Straight Mast

Warehouse

• Class 4 or 6

• Solid and/or pneumatic

• Hard surface, usually level, usually inside

Types of Forklifts

Variable Reach or Telescopic RTFL

• Reaches to greater heights

• Adjustable frame

• Multiple steering modes

• Also known as Shooters, Lull, Telehandler, etc.


Vertical Mast RTFL

• Steering primarily through rear wheels

• Mast tilt feature

• Carriage shift feature

• Tight turning radius

• Efficient in storage rack areas

Types of Forklifts

Warehouse Forklift

• Steering through rear wheels

• Mast tilt feature

• Carriage shift feature

• Tight turning radius

• Efficient in storage rack areas

• Electric, gas or LP


Truck Mounted

• Attached to truck for delivery of heavy loads on-site

• Extremely tight turning radius

This seminar does not include this type of

forklift. Each make and model has its own

training package.

Types of Forklifts

Forklift Selection Questions

• How high do you need to land the load?

• How close can you get the forklift to the work?

• Inside or outside?

• Electric, Gas/LP, Diesel?

• Path from drop off area to work area?

• What work are you doing?

• How much weight are you lifting?


Gear Quizuiz

Types of Forklifts?

1. Rough terrain reach forklifts are also known as

A. Shooters

B. Lulls

C. Telhandlers

D. All of the above

2. Warehouse forklifts can run on ________________________________, gas or LP.

3. An important question to ask when selecting any forklift

is __________________________________________________________________________.

4. An important question to ask when selecting any forklift

is __________________________________________________________________________.

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down



Familiarization and Delivery• Load charts and capacity

• Seat belt

• Engine oil

• Start the engine

• Operation

• Steering and modes

• Fuel fill and type

• Hydraulic fill and check

• Pre-start inspection

Familiarization and Delivery

Manuals and Warning Labels• Operator̕s manual

— Read it!

• Warning labels

— Legible

— Read and heed


ANSI Safety SymbolsFollowing are definitions of labeling you might

encounter on forklifts:

Danger — Immediate hazards which WILL result in severe personal injury or death.

Warning — Hazards or unsafe practices which COULD result in severe personal injury or death.

Caution — Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.

Notice Decal — Indicates gas, diesel, hydraulic oil


Familiarization and Delivery• Fuel

— Clear identification

— Putting the wrong fuel in a machine is a very expensive ($$$) mistake

• Hydraulic

— Locked or bolted


Gear Quizuiz


1. It does not matter what fuel a forklift takes.

True False

2. A Danger label means immediate hazards which ______________________ result in severe personal injury or death.

3. ____________________________________ must be on the machine and ____________________________________ must be legible.

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down



Worksite Hazard Assessment• Can the surface the forklift is to be operated

on support the forklift and its load?

— Holes

— Obstacles

— Power lines

— Phone lines

— Mud

— Soft sand

— Ruts

— Fences

— Standing water

— Streams and ponds

— Large rocks

— Culverts

— Blind spots

— Other workers

— Non-workers

— Survey stakes

FORKLIFT SIGNALS

TILT FORKS DOWNLL

STOP RAISE LOAD LOWER LOAD

TILT FORKS RIGHTLL

MOVE LOAD BACKWARDWW MOVE LOAD FORWARDWW

TILT FORKS LEFTLL TILT FORKS UPLL

Worksite Hazard Assessment

Worksite Hazard Assessment• Site specific rules

• Speed limits

• Hand signals

• Signs

• Communications

• Training I.D.

• Reflective fluorescent vest


Loading Docks• Make sure the brakes are set on the tractor/trailer and dock plate is set between dock and trailer

• OSHA requires you to wheel chock truck/trailer wheels

• Must use jack stands, not landing gear to support front of trailer when not connected to tractor

• Make sure trailer bed can support loaded forklift

• Obstructed visibility, sound your HORN

• Stay away from loading dock edge

• Lighting changes


Racks and Narrow Isles• Be aware of:

— Maneuverability

— Overhead obstructions

— Visibility, sound horn, use your mirrors

— Pedestrians

— Other vehicles

— Can racks support the load

25 Feet of ClearanceNo Storage – No Parking

25 Feet of ClearanceNo Storage – No Parking


Railroad Tracks• Do not park or store materials within 25 feet of railroad tracks

• Cross tracks after stopping and making sure the track is clear of moving cars

• At an angle, slowly


Minimum Safe Approach Distance• Stay at least 10 feet away from overhead power lines including materials being handled on the forklift


Mounting and Dismounting• Three-point contact

— Clean shoes off

— Two feet and one hand or Two hands and one foot always on the machine or ground

— Face the machine

— Sit in the seat, adjust the seat, fasten seat belt

— Do not get off unless forklift is properly shut down

— Do not swing off, slide out, etc.

— Exit facing the machine, maintaining the “three-point contact”


Gear Quizuiz


1. Can the ________________________________ the forklift is to be operated on support the forklift and its load?

2. Stay at least ______________________________________ away from overhead power lines including materials being handled on the forklift.

3. OSHA requires you to _________________________________________

truck/trailer wheels against the loading dock.

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down


Pre-start Inspection

Pre-start Inspection & Personal Protection Equipment (PPE)• Starts with YOU, are you protected? — Steel-toe boots — Hard hat — Safety glasses — Seat belts


Pre-start Inspection • Before the start of the day or before the start of the work shift.

— Operating & emergency controls

— Safety devices

— Personal protective devices, hard hat, safety boots, safety glasses, seat belt, horn, mirrors

— Air, hydraulic, & fuel system leaks

— Cables, wiring

— Loose, missing parts

— Tires, wheels

— Placards, warnings, control markings, manuals

— Outriggers, stabilizers, other structures

— ROPS

— Grab handles and steps

— Forks

— Items specified by manufacturer


Pre-start Inspection• Common problem areas

— Seat belts

— Control markings

— Load charts

— Forks

— Fuel, what kind?

— Brakes


Forks per ANSI/ASME• Forks shall be inspected at intervals not greater than

12 months or whenever permanent deformation is suspected. Severe applications shall warrant more frequent inspection. Inspection records shall be kept. Fork inspection shall be performed by trained personnel. The forks shall be carefully examined for the following:

— Surface cracks, visual check or non-destructive testing

— Straightness of blade and shank, within 0.5% of length of blade or height of shank

— Fork angle from upper face of blade to load face of shank, within 3 degrees of original

— Relative height of fork tips in set when mounted on fork carrier, difference of height not to exceed 3% of length of blade

— Operation of positioning lock (if provided), good repair and correct operation


— Wear, especially in the area of heel, Thickness shall be within 10% of original specification or not less than minimum thickness as specified by the fork manufacturer

— Fit of fork arm mounting hooks or eye, visual check for fit with no excessive wear or deformation between hooks and carrier of fork eye and shaft

— Markings shall be legible

FAN BELT

HYDRAULIC FLUID

HOSES

OIL

BATTERY

COOLANT


Maintenance• Check fuel, what kind?

— Do NOT run out of fuel!

• Drain water separator

• Check oil

• Check radiator, cold

• Watch gauges

• Check fan belt

• Check hoses

• Check tires

• Check battery


RefuelingDo NOT run out of fuel!!!

• Shut off forklift

• DO NOT SMOKE near forklift

• Keep sparks and flame away

• Do not cut or weld

• Know the type of fuel

• Attend fuel nozzle

• Do not overfill

• Report spills

• Refuel at end of day to reduce the amount of condensation that forms overnight inside the tank

• Make SURE you put the right fuel in the fuel tank

• Putting the wrong fuel in the tank is a MAJOR, EXPENSIVE ($$$) mistake

Do NOT run out of fuel!!!


Refueling Liquid Petroleum (LP)• Wear proper PPE, gloves, safety glasses/goggles

• Close LP tank valve

• Start and run forklift until engine stops

• Turn forklift key switch off

• Disconnect LP tank hose

• Inspect connections, hose, valve

• Reconnect new tank hose and latches

• Open valve slowly and observe for leaks, if leak is observed, close valve

• Do not put bare hands near or around hoses or couplings

• Do not use damaged tanks, hoses or couplings

WARNING – Some states require certification training to refill LP tanks.


Maintenance• Battery jumping

• Gas expelled by the battery acid is flammable keep ignition sources AWAY

WARNING – Batteries can explode

The order of battery jumper connectionsConnect 1 to 2, then 3 to 4

Disconnect 4 then 3 then 2 then 1

INCORRECT CORRECT


DANGER — Hydraulic Leaks • Do not put your hands around hydraulic lines, especially

if you suspect a leak

• High pressure injection injuries can be fatal

• If injured by high pressure injection, seek professional medical attention IMMEDIATELY!!!

Your life or limb may depend on immediate action



Name three things to check on a pre-start inspection?

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

Gear Quizuiz

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down


Equipment Operation

Transmission Shifter Forward, Neutral, Reverse1.

Gauges, Fuel, Water Temperature, Oil Pressure, and

Engine RPM2. Fork and Mast Controls

Up and Down, Fork Tilt, and Side Shift3.

4.

Brake Pedal, Creeper Brake, Accelerator5.

Note: Forklift control layouts vary from make to make and model to model. Refer to operating manual for description of each.

Typical Warehouse Controls

Key Switch, Horn, Lights, Accessories

Parking Brake6.


Gauges, Fuel, Water Temperature, Oil Pressure,

and Engine RPM2.

Typical Variable Reach RT Controls

Note: Forklift control layouts vary from make to make and model to model. Refer to operating manual for description of each.

Transmission shifter Forward, Neutral, Reverse1.

Frame Tilt Level Indicator3.

Boom Up, Down, Extend, Retract, Fork Tilt Switch5.

8.Electric Parking Brake

Brake Pedal, Accelerator7. Outrigger

Stabilizer Control6.

4.Horn, Steer Mode

Switch, Key Switch, Lights, Accessories

Equipment Operation

Forklift Operation• When starting, make sure your seat is adjusted tight across your hips and your seat belt is fastened

• Electric parking brake must be set, ON in order for forklift to start

• Hand brake (mechanical) must be set to start

• Transmission selector must be in NEUTRAL in order for the forklift to start

• Put your left foot on the brake when starting

• Turn the key


Forklift Attachments• Must be authorized by the manufacturer

• Must be on I.D. plate and load chart

• Must work within the design limitations of the forklift

• Per OSHA and ASME/ANSI

Equipment Operation

Load Charts• Maximum weight to reach limitations

• Know the weight of objects to be picked up or deposited

• If you cannot determine weight, ask a supervisor or supplier

Sample Load Chart: Gradall 534D-6

Height range in feet

Boom angle indicator, in degrees

Range of capacity in pounds

Distance in feetin front of the tires

Numbers or letters on fly boom sections, indicate distance

fly boom is extended


Load Center• Most forklifts are designed and tested to a 24̕̕ load center

• Designed to pick up a 48̕̕ x 48̕̕ x 48̕̕ cube with the load laterally centered

• Stick and brick demonstration

UnknownZone

Load Center24”

Load Center

UnknownZone

24”Forks

Equipment Operation

Load Charts

Q. You are assigned to drive a warehouse style forklift, like the 5,000 lb. Komatsu FG25T-12 188

with side shift to do some work in the yard. What is the maximum lifting capacity of this forklift?

A. 5,000 lb.

B. 4,030 lb.

C. 3,750 lb.

D. I really do not know, but I will check the load chart before I operate the forklift.

A. The correct answer is d. and c. 3,750 lb. The three-stage mast and the side shift both take

away capacity from the original 5,000 lb. With the 188̕̕ (15̕8̕̕ ) high mast and side shift the capacity of this forklift is 3,750 lb. Always refer to load chart for

actual lifting capacities of all forklifts.


Load ChartsWhy the limited capacity?

— Mast height and reach

— Side shift all take away from capacity

DANGER — Forklifts may pick up larger loads from the ground, but may tip when mast is raised, tilted, the boom is extended, or the load is side shifted.

LoadCenter

NewLoadCenter

OriginalLoadCenter

FulcrumPoint

Counterweight

Equipment Operation

Straight Mast Limitations• Three Stage Mast 15̕ lifting height:

— 15̕ lifting height and now 2,500 lbs. rated capacity

— Original 5,000 lb. rated capacity X 24˝ load center = 120,000 in. lbs.

— 120,000 in. lbs. / new load center of 48˝ = 2500 lbs. rated capacity

— The higher the mast, the further the load arcs away from the counterweight, thereby lowering the rated capacity. NOTE: The additional weight of mast sections and options like side shift adds weight which will reduce the rated capacity not calculated in this example.


Load Charts

Q. You are operating a reach forklift with a 6,000 lb. load rating according to the load chart in the

cab. The load you are picking up is right in front of the forklift and you will not have to extend the boom to pick and place the load. The load weighs 5,000 lb. but the load center is at 36̕̕ from the back of the forks. Can this lift make the lift?

A.The correct answer is No. You can calculate the actual load on the forklift this way.

6,000 lb. rating X 24˝ load center = 144,000 inch-pounds.

Then, 144,000 inch-pounds divided by 36 inch load center =

4,000 lb. load limit.

So, this 6,000 lb. forklift can now only pick up 4,000 lb. if the load center is 36 .̋ This calculation works for all forklifts. Load centers are usually always 24 .̋

Equipment Operation

Load CenterFormula• Load capacity × inches to rated load center = inch pounds

• Then, inch pounds ÷ by the actual load center = actual capacity


Slinging the Load• It is not recommended to sling a load from a forklift due to risk of:

— Tip-over

— Hitting something or someone

• If you do, sling a load from a forklift

— Place sling on both forks at or behind 24̕̕ from rear of forks

— Tether the load, so it does not spin or swing

— Keep boom as low as possible

— Be aware that traveling with the boom raised is extremely dangerous and can cause tip over

Equipment Operation

Stability• Constantly changing

• Tilt forward

• Tilt back

• Driving – speed

• Steering

• Center of gravity

• Forklifts become more stable with a load and can be unstable without a load

• Steel ball on a string


Stability• Straight mast at rest

Center of gravity – Imagine a large steel ball hanging

from a string

Figure 1.

Equipment Operation

Stability• Straight mast

• Mast raised with load

Center of gravity moves forward and up as load

is raised.

Figure 2.


Stability• Variable reach

• Without load

• Least stable

Reach forklift center of gravity moves back and up as empty

boom is raised.

Center of gravity moves very close to rear and narrow part of stability triangle. Not being on level surface or a sudden movement or

stop could cause forklift tip over.

Figure 3.

Equipment Operation

Stability Without a LoadVariable Reach

Center of Gravity

• Boom up

• No load

• Least stable

Rear of stability triangle

Figure 4.

Top view is for illustrative purpose only

NoLoad


Stability With a LoadVariable Reach

With load, center of gravity moves forward.


Center of Gravity

• Boom up

• No load

• Least stable

Figure 5.

Top view is for illustrative purpose only

Load

Equipment Operation

StabilityVariable Reach on Slope

Center of Gravity

• Outside stability triangle

• Boom up

• No load, after load deposit

• Least stable


Figure 6.


StabilityCenter of Gravity

• Boom up

• No load

• Least stable

Rear of stability triangle is very narrow

Figure 7.

Equipment Operation

StabilityCenter of Gravity

• Boom up

• No load

• Least stable

• Level the machine

Rear of Stability Triangle is very narrow.

When center of gravity moves outside this area forklift will tip.

Figure 8.


Driving Without a Load

Always keep load (counterweight) above head, when there is no load on forks.

This would be the correct way to load the forklift onto a trailer.

NoLoad

Counterweight

Figure 9.

Equipment Operation

Driving With a Load

Always keep load above your head, up hill.

Load

Figure 10.


Stability Without a LoadReasons for Forklift Tip-over

• Overloading ......................................... Do not overload

• Sudden turns ............................................. Smooth turns

• Sudden acceleration ...............Smooth acceleration

• Sudden stops ........................................ Smooth braking

• Not level ............................................................. Keep level

• Frame tilt with load ...................................... Keep level

• Slopes ................................................................... Keep level

• Swinging loads ................................ Smooth operation

DANGER The further the center of gravity moves to the rear the less range it has to move across or side to side and still remain inside the stability triangle.

Equipment Operation

Seat Belt• On forklifts, a seat belt is required in order to:

— Prevent you from falling out of seat if a tip over occurs

— Keep you within the protection of the ROPS

— Keep you from getting up and wanting to get out

DANGER — Should the machine start to tip over, grasp the steering wheel tightly to keep both hands inside the ROPS canopy and lean away from the point of impact. NEVER attempt to jump clear. Should you attempt to jump clear, you could be injured or killed.


Forklift Stability• Keep these points in mind:

— Keep boom/forks/load low

— Cradle load

— Slow machine down

— Accelerate and brake gently

— Level the forklift or reposition

— Do not frame tilt with boom raised

Equipment Operation

Slope vs. Degrees

Percent Slope 0 10 20 30 40 50 60 70 80 90 100 120 140 170 200

Degrees 0⁰ 6⁰ 11⁰ 17⁰ 22⁰ 27⁰ 31⁰ 35⁰ 39⁰ 42⁰ 45⁰ 50⁰ 55⁰ 60⁰ 64⁰

Percent Slope to Degrees Conversion

Percent Slope 10% 1 2 3 4 5 6 7 8 9 10 1 foot rise on 10 foot of run = 10% Slope or 6⁰


Load Pickup and CapacityKnow the weight of the load. Refer to bill of lading slips, catalog weights, weight indicated on material or equipment, etc.

Material Weight in Lbs/Cubic Foot

Weight in Lbs/Cubic Yard

Weight in Lbs/48" Cube

Weight Multiples

Scaffold Boards 16 ft. 70 lbs. 25-1750, 50-3500Scaffold Boards 12 ft. 50 lbs. 25-1250, 50-2500Scaffold Boards 8 ft. 35 lbs. 25-875, 50-1750Scaffold Frame 6 x 5 50 lbs. 25-1250, 50-2500Scaffold Frame 5 x 5 40 lbs. 25-1000, 50-2000Braces 10 lbs. 25-250, 50-500Screwjacks 6 lbs. 25-150, 50-300Aluminum boards 7 ft. 28 lbs. 20-560, 40-1120Aluminum boards 10 ft. 44 lbs. 20-880, 40-1760

19 foot scissor lift 2900 lbs.20 foot scissor lift 4000 lbs.26 foot scissor lift 5400 lbs.

PVC pipe sch 40 1" OD 0.32/ft.PVC pipe sch 40 2" OD 0.82/ft.PVC pipe sch 40 3" OD 1.44/ft.

Cellular concrete 25-44 675-1188 1600-2816Brick silica 128 3456 8192Brick 120 3240 7680Water 63 1701 4032 8 lbs./gallon 5-40, 55-440Tar 72 1935 4608Sand 120 3240 7680Cement 94 2538 6016

Forklift WeightsReach Forklifts Weight in PoundsLull 644E-42 24,000Lull 944E-42 27,000Lull 1044C-54 31,000SkyTrak 6036 21,000SkyTrak 6042 24,000SkyTrak 8042 25,500SkyTrak 10042 26,500SkyTrak 10054 27,500

Reach Forklifts Weight in PoundsGradall 534D9-45 24,500Gradall 534D10-45 25,500

Warehouse Forklifts Weight in PoundsKomatsu G25T-188 9,000Komatsu FG30HT-12 10,800Komatsu FG45T2-7 15,000Komatsu FD70T-7 22,000

Equipment Operation

Automobile vs. Forklift

• Suspension

• No hydraulics

• Front wheel steer

• Stability constant

• Trans control on right

• High speed travel

• Prepared roads

• Carry passengers

• Visibility

• Weight

• Enclosed cab

• Tires act as suspension

• Hydraulic lifts

• Various steer modes

• Stability varies

• Trans control on left

• 0-20 MPH

• Rough terrain

• Carry materials

• Visibility obstructed

• Heavy weight

• Open cab

Automobile Forklift


General Safety Guidelines• Know how to obtain assistance

• Know first aid kit location

• Never smoke near equipment

• Be aware of ventilation

• Visibility, use mirrors and horn

• Know your pinch points

• Never operate the forklift unless you are in the seat with the seat belt fastened

• Never leave the seat with forklift running

• Never put boom, mast or load over any persons

• Watch for overhead obstacles

• Wear proper clothing and PPE

• Do not wear jewelry, loose clothing

Equipment Operation

Steering • Four wheel steer

• Tail swing

• Fork swing

• Always realign the steering to the straight position before changing the steer selector.


Steering• Two wheel rear steer

• Warehouse

• Gradall brand

• Always realign the steering to the straight position before changing the steer selector

Equipment Operation

Steering• Crab steer or oblique

• Always realign the steering to the straight position before changing the steer selector

• Should only be used to get into or out of tight spots


Steering• Four wheel steer

• Always realign the steering to the straight position before changing the steer selector.

Equipment Operation

Before Load Deposit• Never put boom/load over people

• Be certain landing point can support the load

• Landing should be level

• Make sure path is clear

• Stop the machine and set parking brake

• Place in neutral, do not drive the load in (except straight mast)

• Level forklift

• Then raise the boom/load to the landing point

CLEARANCE


Load Deposit and After• Never put boom/load over people

• Place carefully

• Observe landing

• Tilt forks forward

• After load is placed, center of gravity changes

• Extract forks with boom, do not drive the forks out (except straight mast)

• Lower path clear

• Lower boom/forks

• Look around before travel CLEARANCE

Equipment Operation

Equipment Operation

1. _______________________________ forks back to cradle the load, _____________________________ forks forward to land the load.

2. Oblique or crab steer should only be used when trying to get into or out of tight spots.

True False

3. Before you can lift a load you must know the _________________________________ of what you are picking up.

4. Keep the ___________________________ and __________________________

low while traveling.

Gear Quizuiz

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down


Shut Down

Shut Down• Always park on level

surface or chock wheels

• Lower forks/boom/mast to the ground, point forks down

• Neutralize controls, transmission selector in neutral

• Set parking brake

• Idle engine

• Shut off key switch

• Cycle hydraulics

• Remove key

• Unfasten seat belt

• Dismount properly

• Chock wheels

• Lock any anti-vandalism

• Refuel

Gear Points

1. Introduction

2. Why Are We Here?






8. Shut Down


SUNBELT RENTALS Forklift Safety Guidelines

TestCircle the correct answer

1. A “DANGER” warning label means A. Hazards or unsafe practices which COULD result in

minor personal injury or product or property damage

B. Immediate hazards which WILL result in severe personal injury or death

C. Hazards or unsafe practices which COULD result in severe personal injury or death

D. Be careful

2. A qualified person is one whoA. Has attended this seminar

B. Has a college degree

C. Has worked in an industry for many years

D. One who by possession of a recognized degree, certificate, or professional standing, or by extensive knowledge, training, and experience and has successfully demonstrated his/her ability to solve or resolve problems related to the subject matter, the work, or the project.

Forklift Examination

3. If an operating manual is missing from a forklift A. You can operate the lift only if you know

what your doing

B. The lift is red tagged DOWN and cannot be operated until the manual is replaced on the machine

C. You can operate the machine only under the supervision of a supervisor

D. You can operate the machine only if your supervisor says so

4. A pre-start inspection is done A. Before the start of the day

B. Before the start of the work shift

C. Every time I get on the forklift

D. Either A or B

5. A pre-start inspection does not include A. Personal protective devices

B. Soil condition

C. Operating manuals

D. ROPS


6. If the seat belt is not operating properly A. Operate the machine anyway

B. Do not jump from the lift should it start to tip

C. Red tag and down the machine until it is repaired

D. Take the day off with pay

7. Workplace inspections are required A. Only before work starts

B. Only after work starts

C. Only during work

D. Before the forklift is used and during use

8. Workplace inspections include A. Mud and water

B. Culverts

C. Electrical wires

D. All of the above and more

9. Wear proper clothing, __________________ _________________ , ____________________ ____________________ , steel-toe boots, gloves, and when appropriate, hearing protection, reflective clothing, wet weather gear, cold weather gear, respirator/filter mask.


10. You are required to stay at least A. 5 feet away from overhead power lines

B. 8 feet away from overhead power lines

C. 10 feet away from overhead power lines

D. 20 feet away from overhead power lines

11. Seat belts are required to be worn to A. Keep you from being tossed around in the cab

B. Keep you in the seat should you hit something

C. I don̕t wear one, I don̕t know

D. Keep you in the seat and within the protection of the ROPS in case the forklift should tip over

12. When carrying a load it does not matter which direction I drive up or down a ramp.

True False

13. Carrying a swinging load with a sling is A. No different than any other load

B. Has special concerns because the swinging of the load can cause the forklift to tip

C. Is not recommended

D. All of the above


14. It is OK to operate a forklift from a floating vessel A. If you can get the insurance

B. If the manufacturer approves it in writing

C. If the vessel is docked

15. While driving a Rough Terrain Reach forklift in rutted muddy terrain with a load

A. Drive slowly and steadily

B. Keep the load as low as is practical

C. Adjust the frame tilt to keep the load and forklift level

D. All of the above

16. It is OK to leave the forklift running and leave the seat to adjust a load as long as I set the brake.

True False

17. I should check the fuel A. After the tank runs out and the engine stops

B. Every day

C. At the end of every day and top off the tank at the end of the day

D. During the pre-start check and at the end of every day and top off the tank at the end of the day


18. The weight of a lift on all the tires is always distributed equally.

True False

19. The further the center of gravity moves to the rear of the stability triangle the less range it has to move _________________ and still remain inside the stability triangle.

A. Up and down

B. Laterally (across or side to side)

C. Front to back

D. Any of the above

20. When doing my pre-start check of the forklift I should

A. Always check the fuel level

B. Always check the fuel level and type of fuel used

C. Always check the fuel level, type of fuel used and the engine oil level

D. What̕s a pre-start check?

21. Stability of a forklift never changes as the load is raised, tilted forward and tilted back.

True False


22. As a trained forklift operator if I am asked to lift a load that I think is unsafe, I should

A. Quit and find another job

B. Make the lift anyway and hope for the best

C. Discuss my concerns with my supervisor and make every attempt to make the lift in a safe manner

D. All of the above

23. If during my pre-start check I discover that the hydraulic oil is low I should

A. Fill it up

B. Don̕t worry about it

C. Call the service department

D. Fill it with diesel fuel

24. The part of the boom that extends out from the main boom section on a variable reach forklift is called the

A. Fly boom

B. Knuckle boom

C. Tower boom

D That thingy that extends out


25. When conducting the pre-start inspection I should check the fuel level in the tank and the type of fuel every time.

True False

26. A typical 6,000 variable reach forklift weighs about A. 12,000 lbs.

B. 10,000 lbs.

C. 5,000 lbs.

D. 24,000 lbs.

27. The most common forklift accident is A. Struck by material

B. Worker fell off forklift

C. Forklift ran off dock

D. Tip-over of forklift

28. Please refer to the load chart for the Gradall 534D on page 68, if the load is 4,000 lbs. what is the maximum distance in front of the machine that the load can be lifted

A. 14 feet

B. 36 feet

C. 20 feet

D. 12 feet


29. Should the forklift start to tip over A. Grab the steering and lean away from the point of impact

B. Jump off

C. Scream and yell

D. Grab the steering wheel with both arms and hands tightly to keep your hands inside the ROPS and lean away from the point of impact

30. 50 16̕ scaffold boards weigh A. 3,250 lbs.

B. 3,000 lbs.

C. 3,500 lbs.

D. 1,750 lbs.

31. Once I complete my workplace inspection I do not need to do an inspection while operating the forklift.

True False

32. When getting on and off of a forklift always A. Maintain a three-point contact

B. Make sure you have your lunch with you

C. Maintain a three-point contact, facing the machine

D. Check the oil

Special thanks to the entire Sunbelt Rentals Safety Department and for the constructive input from all the safety training classes conducted

within Sunbelt, without which the production of this booklet and seminar would never have been possible.

DRAWINGS AND ILLUSTRATIONS FOR INSTRUCTIONAL PURPOSES ONLY.

Drawings and illustrations by Jeff Stachowiak of Sunbelt Rentals© Copyright 2010 All Rights Reserved

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