هیدرولیک تخصصی

2008

09125835759منصور ابوالقاسمی

Forklift Safety Training Class

Contents

• Forklift safety

• Introduction

• Training and Standards

• CD# One –

Forklift Fundamentals

• Review Quiz# One

• CD# Two –

Forklift Operations

• Review Quiz# Two

• Types of Forklifts

• Maintenance

• Day-to-Day Considerations

• Daily Checklist

• Refuel procedures

Do’s & Don’ts

• Conclusion


Forklift Safety

Learning the safe

way to operate a forklift …

…may save your life


A forklift is a powerful tool that allows

one person to precisely lift and place

large heavy loads with little effort.

Using a tool such as a forklift, cart or

hand truck instead of lifting and

carrying items by hand can reduce the

risk that you will suffer a back injury.

However, there is great risk of injury or

death when a forklift operator:

· has not been trained in the principles of physics that allows it to lift heavy

loads,

· is not familiar with how a particular forklift operates,

· operates the forklift carelessly, or

· uses a forklift that is not safe due to malfunctioning or missing parts.

Introduction


Introduction

Every year nearly 100 workers are killed and 20,000 are seriously injured in

forklift mishaps. According to the National Traumatic Occupational Fatalities

(NTOF) Surveillance System 1530 workers field from forklift related accidents

between 1980 and 2001. At least 22% of these deaths were caused by forklift

overturns and another 20% to workers on foot being struck by the forklift. With

well over one million forklifts in operation today, emphasis must be placed on

both worker and pedestrian safety.


Forklift Fatalities, 1992-1996

86 89

120

95

114

1992 1993 1994 1995 1996

Source: Bureau of Labor Statistics, Job Related Fatalities Involving Forklifts


Forklift Fatalities by Age Group

1992 -1996

3%

10%

22%

21%

12%

5%

27%

Under 20

20 - 24

25 - 34

35 - 44

45 - 54

56 - 64

65 & over


Industries Where Powered Industrial Truck

Accidents Occurred

Source: OSHA Fatality/Catastrophe Reports, complied by OSHA Office of Electrical/Electronic and

Mechanical Engineering Safety Standards.


Nonfatal Occupational Injuries and

Illnesses by Source, 1996

Source: Bureau of Labor Statistics, Job Related Fatalities by Selected Characteristics, 1996.


An effective material safety program is required

to limit accidents. An important part of this program

Is operator selection and training. There are federal and

Industry standards which cover both operator selection

and training.

OSHA Standards require that the employer ensure that a :

1. Forklift operator is competent to operate the forklift he or she is

assigned to use.

2. The employer must document operator training and an evaluation of

the operator’s performance while using the forklift.

A copy of the Osha Standards –

Subpart N-Materials Handling and Storage.

Section 1910.178, Powered industrial trucks

Will be on hand in the Shipping and Receiving department.

Training and Standards


Operator Training pt1• Safe operations

– The employer shall ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by successful completion of the training and evaluation specified in the OSHA standard.

– 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 required training (or previously received appropriate training).

A copy of the Osha Standards – Subpart N-Materials Handling and Storage.

Section 1910.178, Powered industrial trucks will be on hand in the Shipping and Receiving department.


Training Program Implementation

• Trainees may operate a powered industrial

truck only:

– Under direct supervision of a person who

has the knowledge, training, and

experience to train operators and evaluate

their competence; and,

– Where such operation does not endanger

the trainee or other employees.


Training Program Implementation

(continued)

• Training shall consist of a combination of:

– Formal instruction (e.g., lecture, discussion,

interactive computer learning, written

material),

– Practical training (demonstrations and

exercises performed by the trainee), and

– Evaluation of the operator’s performance in

the workplace


Training Program Implementation (continued)

• Training and evaluation

shall be conducted by a

person with the

knowledge, training and

experience to train

powered industrial truck

operators and evaluate

their competence.


Refresher Training and Evaluation

• Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely.

• Refresher training required when:– Unsafe operation

– Accident or near-miss

– Evaluation indicates need

– Different type of equipment introduced

– Workplace condition changes


Powered Industrial Trucks -

Operator Training

1910.178 (l)

1915.120 (a)

1917.1 (a)(2)(xiv)

1918.1 (b)(10)

1926.602 (d)


Powered Industrial

Truck - Definition

• A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier materials. [American Society of Mechanical Engineers (ASME) definition]

• Excluded are vehicles used for earth moving and over-the-road hauling.

• Commonly known as forklifts, pallet trucks, rider trucks, fork trucks, or lift trucks.

• Can be powered through electric or combustion engines.


Performance-Oriented

Requirements

• The powered industrial truck operator

training requirements are performance-

oriented to permit employers to tailor a

training program to the characteristics of

their workplaces and the particular types

of powered industrial trucks operated.


Refresher Training and Evaluation (continued)

• An evaluation of each powered industrial

truck operator’s performance must be

conducted:

– After initial training,

– After refresher training, and

– At least once every three years


Forklift Fundamentals

CD# 1

17 minutes


1.) each forklift is designed to perform specific tasks in set situations

and should never be used in any other way.

True or False

2.) OSHA requires that you be qualified for each type of forklift and

each kind of work Situation you encounter.

True or False

Review Quiz


Forklift Operations

CD# 218 Minutes


1.) Using good judgment on every load and carry is the mark of a

professional forklift operator.

True or False

2.) In the traveling position, the forks are about one foot above

the floor.

True or False

Review Quiz


A forklift is a type of “powered industrial truck” covered by OSHA standards. Like

other powered industrial trucks, its purpose is to move carry, push, pull, and lift a

material load then stack it or place it in a storage rack (tier). Forklifts come in

many sizes and capacities. They can be powered by batteries, propane, gasoline

or diesel fuel. Some are designed to be used in a hazardous location or

atmosphere where an ordinary forklift might cause a fire or explosion.

Powered industrial trucks are classified into seven types based on their

characteristics.

• Class 1 - Electric Motor, Rider, Counter-Balanced Trucks (Solid

Pneumatic Tires)

• Class 2 - Electric Motor Narrow Aisle Trucks (Solid Tires)

• Class 3 - Electric Motor Hand Trucks or Hand/Rider Trucks

• Class 4 - Internal Combustion Engine Trucks (Solid Tires)

• Class 5 - Internal Combustion Engine Trucks (Pneumatic Tires)

• Class 6 - Electric and Internal Combustion Engine Tractors

Pneumatic Tires). There are no forklifts in this class.

• Class 7 - Rough Terrain Forklift Trucks (Pneumatic Tires)

Types of Forklifts


Good maintenance practices are essential to keep trucks

safe and productive. Maintenance procedures must also be

safe for those who perform the maintenance

Trained Mechanics

Mechanics must be trained in safe maintenance

and repair practices, such as

1. securing moveable parts,

2. proper use of tools,

3. wearing of protective clothing,

4. use of protective equipment.

5. And safe operating procedures of the forklift trucks

and their attachments.

Maintenance


Day-to-Day Considerations

Onsite Considerations

• Pedestrians

• Daily Checks

• Lifting & Transporting

Loads

• Charging

• Do’s & Don’ts

• Forklifts capacities –

Diesel 3000 lbs,

Gas (old yellow) 6000 lbs-

Electric 2000 lbs

• Rough Terrain –

Extended-reach FLT –

Additional attachments include lift cage, a fabricated attachment for forks

to lift extra long pallets, a small fabricated attachment to tow trailers,

and a attachment /w chains to lift shelters and generators.


Daily Checklist

• Tires

• fluid levels

• Chains

• Horn

• Lights

• Water

• Steering

• Mast

• Battery

• Hydraulic leaks


REFUELLING and

BATTERY MAINTENANCE

• Diesel

• Gas

• Electric


DIESEL & GAS FUEL

• Use refuelling area –Our Refuelling area is behind

shipping and receiving, across from the warehouse

#2. Fire Extinguisher, Gloves, and Dry Sweep are

available .

• Turn off engine and

use parking brake

• Avoid overfilling the fuel tank

• Refuel forklifts when gage reads ½ and below* Always strap equipment before movement

* Always use Ground Guides


BATTERY CHARGING

• Change in a well ventilated area - Motor

pool

• Use eye protection when making

connections

• Have eye wash facilities available

• Have an acid neutralizing agent

available

• Don’t over fill the batteries with water

“DON'T”

• DO NOT– Consume alcohol while at work

– Pick up a load if someone is standing close

– Allow people to walk underneath the load

– Try to pick up an unsuitable load

– Leave a lift truck unattended with the engine running

– Carry passengers

– Drive over cables or piping

– Operate with the load raised except at creep speed

– Drive forward if visibility is impaired by a load

– Make sharp turns, only turn at creep speed

– Alter, remove or disconnect any mechanical or safety devices on any forklift. ONLY AUTHORIZE PERSONNEL CAN .


“DO’S”

• DO…..– Only issue keys to authorized drivers

– On completion of work, park lift truck in designated area

– Be careful with pedestrians / obey site rules / speed limits

– Sound horn at potential danger spots

– Stop before entering building, sound horn then proceed

– Avoid violent breaking

– Travel slowly down slopes with the fork facing uphill

– Always use the hand brake when necessary

– Never travel across an incline

– Before you raise a load check over head for obstructions

– Always check for traffic when dismounting

– Avoid driving over wet, grease and oil spilled areas

– Report all accidents and safety violations to your supervisors immediately.


Certification

• The employer shall certify that each operator has been trained and evaluated as required by the standard.

• Certification shall include:

– Name of operator

– Date of training

– Date of evaluation

– Identity of person performing the training or evaluation


Any Questions?

We have a two part test before

CertificationA Written and a Driving test

Good Luck

Conclusion


The End
