Introduction:
Industrial workplaces have come to rely on forklift trucks
for their ability to lift and transport just about any load around the plant.
The power of forklifts makes them indispensable, but also dangerous. Often when
employees accustomed to using forklifts they tend to stop thinking of them as a
safety hazard, and forget or neglect to follow some important operating and
maintenance procedures. When forklift injuries occur, they’re usually serious
given the tremendous weight of those powerful machines.
Employees and workers must be trained to work safely with
forklifts, not just when they’re hired but periodically thereafter. Refresher
training for the experienced operator is just as important as first-time
training for new employees.
Forklift Inspection:
Although forklifts are designed to perform rugged tasks,
each time they are used they can get damaged in any number of ways. That’s why
inspection is of critical importance. At the start of each shift, perform both
a visual inspection of the general condition and cleanliness of the lift truck,
as well as an operational check to test its proper functioning. If you notice
anything that may affect the normal operation of the forklift, immediately
alert your supervisor.
Checklist for Visual
Inspection:
·
Floor-clear of objects that could
cause an accident.
·
No obstruction overhead.
·
Note any nearby objects to avoid as
you drive away.
·
Fire extinguisher present and
charged.
·
Engine oil level, fuel level,
radiator water level.
·
Battery fully
charged and securely in place.
·
Cables for exposed wires.
·
Battery plug
connections not loose, worn or dirty.
·
Vent caps not clogged.
·
Electrolyte level in cells.
·
Bolts, nuts, guards, chains, or
hydraulic hose reels not damaged, missing or loose.
·
Wheels and tires not worn or damaged.
·
Forks not bent or cracked.
·
Chain anchor pins not worn, loose or
bent.
·
No damp spots or drips that may
indicate a leak.
Checklist for Operational Pre-Use
Inspection:
ý
Horn working and loud enough to be
heard in working environment, other warning devices operational.
ý
Floor brake: pedal holds, unit stops
smoothly.
ý
Parking brake: holds against slight
acceleration.
ý
Deadman seat brake: holds when
operator rises from seat.
ý
Clutch and gearshift: shifts smoothly
with no jumping or jerking.
ý
Dash control panel: all lights and
gauges operational.
ý
Steering: moves smoothly.
ý
Lift mechanism: operates smoothly
(check by raising forks to maximum height then lowering completely).
ý
Tilt mechanism: moves smoothly, holds
(check by tilting mast all the way forward and backward).
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Cylinders and hoses: not leaking
after above checks.
ý
No unusual sounds.
Only qualified people are permitted to
service and maintain forklift trucks.
Forklift Operation:
No
one must ride or operate a forklift truck except for a trained forklift
operator who is able to maintain control of the forklift and operate it
smoothly when stopping, starting, lifting and tilting.
Guidelines on Forklift Safety:
A- Traveling:
1.
Keep your hands, arms, head, feet and
legs inside the forklift.
2.
Travel with forks as low as possible
from the floor and tilted back.
3.
Obey posted traffic signs.
4.
Decrease speed at corners, sound horn
and watch the swing of both the rear of the lift truck and the load.
5.
Avoid sudden stops.
6.
If the load blocks your vision,
travel slowly in reverse.
7.
Always look in the direction of
travel.
8.
Keep an eye out for oil spots, wet
spots, loose objects, holes, rough surfaces, people, and vehicles on the floor
or roadway.
9.
To ensure the safety of others, know
the blind spots of the lift truck with and without a load. When anyone crosses
the route being traveled, stop the forklift truck. Lower the load to the floor,
and wait until passage is clear.
B- Traveling on an Incline:
1.
Keep the forks pointed downhill
without a load, and pointed uphill with a load.
2.
Do not attempt to turn the lift truck
until it’s on level ground.
C- Steering:
1. Support the load by the front wheels and turn with the rear wheels.
2. Do not turn the steering wheel sharply when traveling fast.
3. If the lift truck is overloaded, steering will be difficult.
4. Do not exceed load limits, and do not add a counterweight as an attempt
to improve steering.
D- Loading:
1.
It’s important to know the recommended
load limit of the forklift (shown on the data plate) and the capacity of the
fork, and never exceed these limits.
2.
Position the load according to the
recommended load center. Do not add extra weight to counterbalance an overload.
3.
Keep the load close to the front
wheels to keep the lift truck stable.
4.
When inserting the forks, keep the
mast of the forklift in an upright position before inserting the fork into a
pallet. Level the fork before inserting it.
5.
Spread the forks as widely as
possible for even distribution.
6.
Drive under the load until it
slightly touches the carriage. Tilt the forks back to shift the weight of the
load back, making it more stable.
7.
If the load is unbalanced, keep the
heavier end closer to you. Tilt the mast back.
8.
Keep the forks 4 to 8 inches above the ground
to avoid potential ground hazards.
E- Raising the Load:
1.
Do not raise or lower the fork unless
the lift truck is stopped and braked.
2.
Avoid lifting a load that extends
above the load backrest if there is any risk of the load, or part of it,
sliding back towards the operator.
3.
Check for adequate overhead clearance
before raising a load, and maintain a safe working distance from overhead power
lines.
4.
Lift the load straight up, then tilt
back slightly.
5.
Watch that the load doesn't catch on
adjacent loads or obstructions.
6.
Don’t back up until the forks are
free.
7.
When a load is raised, the lift truck
is less stable. The operator must stay on the forklift when the load is in a
raised position.
8.
Don’t allow anyone to stand on the
forklift or walk under the elevated part of the forklift, whether it’s loaded
or unloaded.
F- Handling Pallets:
1.
Ensure that forks are level and high
enough to go into the pallet, and that they go all the way under the load.
2.
Forks must be proper width to provide
even weight distribution.
3.
Avoid trying to move or adjust any
part of the load, the forklift or the surroundings when on the forklift.
4.
Do not use pallets elevated by
forklifts as an improvised working platform.
G- Unloading:
1.
Turn the forklift slowly into
position.
2.
If unloading into a truck, before
driving straight in, make sure the rear wheels of the truck are chocked, the
brake are locked, and the dock plate is secure and won’t move. Then drive in,
position the load, tilt if forward and release it.
H- Parking:
1.
Park only in an approved location.
2.
When leaving the lift truck
unattended, secure it by setting the brakes, lowering the forks or load to the
floor, neutralizing the controls, and turning off the motor switch and remove
key.
3.
Forklift will be considered
unattended if the driver is away by more than 25 ft.)
4.
Do not block aisles, doors, exits,
electrical panels, fire extinguishers.
I- Refueling:
1.
Only trained personnel should refuel
forklifts.
2.
Refueling area should have
appropriate fire warnings and emergency equipment available.
3.
Turn off forklift and set brake and
never smoke around the forklift.
4.
Start fueling and clean up spills
quickly.
Forklift Balance and Stability:
How to calculate the load in case of
increase in the distance B than what is mentioned in the name plate of the
truck?
(A + B) X C = INCH POUNDS
C: Truck’s Capacity in Pounds
Example:
You operate a lift truck that is rated at 5000 lbs. at 24” LC.
You must lift a load with an LC of 36”
The distance from the center of the front wheels to the face of the forks
is 18”.
What is the maximum weight you can lift?
Step One:
You must first determine the maximum
Inch Pound Capacity of the truck.
(18”
+ 24”) X
5000 = 210,000 Inch
Pounds
Using the equation where A = 18” and B = 36” and Inch Pound = 210,000 Inch Pound.
(18” + 36”) X ? = 210,000 Inch Pound.
(54”) X ? = 210,000
Lbs
= 210,000 / 54”
= 3888 lbs.
