1. Fork Lift Safety E Light Electric Services, Inc 2012 E Light Electric Services, Inc. 20121

2. Features Rough terrain forklift –versatile material handler –capable of moving thousands of pounds over rugged surfaces E Light Electric Services, Inc. 20122

3. Session Objectives Identify rough terrain forklift hazards Understand stability principles Follow basic safety rules Inspect forklifts and worksites for safety Load, unload, and travel safely Prevent tip-overs E Light Electric Services, Inc. 20123

4. Pre-quiz: True or False? How Much Do You Already Know? Most rough terrain forklift accidents are caused by operator error. The weight of the load does not affect stability. Anyone who has driven an all-terrain vehicle is permitted to operate a rough terrain forklift. You should check weight charts when loading E Light Electric Services, Inc. 20124

5. Hazards Tip-overs/rollovers Collisions Slopes/edges Confined areas Obstructions Terrain –Dips, holes, trenches, excavations Soft ground, E Light Electric Services, Inc. 20125

6. Accidents Most accidents are caused by operator error E Light Electric Services, Inc. 20126

7. Forklifts 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(s) performing the training or evaluation –Class of Fork lift E Light Electric Services, Inc. 20127

8. Forklifts The Industrial Truck Association has placed powered industrial trucks into 11 classes. –These classifications are based on the type of engine or motor and the atmosphere they to operate in. E Light Electric Services, Inc. 20128

9. Powered Industrial Trucks. - 1910.178..1910.178(l) (l) Operator training. (l)(1) Safe operation. (l)(1)(i). –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)(1)(ii). –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). E Light Electric Services, Inc. 20129

10. Powered Industrial Trucks. - 1910.178 (l)(2) Training program implementation. (l)(2)(i) –Trainees may operate a powered industrial truck only: (l)(2)(i)(A) –Under the direct supervision of persons who have the knowledge, training, and experience to train operators and evaluate their competence; and. (l)(2)(i)(B) –Where such operation does not endanger the trainee or other employees. E Light Electric Services, Inc. 201210

11. Powered Industrial Trucks. - 1910.178 (l)(2)(ii) –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 operator's performance in the workplace. (l)(2)(iii) –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. E Light Electric Services, Inc. 201211

12. Powered Industrial Trucks. - 1910.178 (l)(6) –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. –(l)(4)(iii) –An evaluation of each powered industrial truck operator's performance shall be conducted at least once every three years. E Light Electric Services, Inc. 201212

13. OSHA Requirements Operating instructions, warnings, and precautions Differences between the truck and the automobile; Controls and instrumentation Engine or motor operation Steering and maneuvering E Light Electric Services, Inc. 201213

14. OSHA Requirements Visibility Fork and attachment adaptation, operation, and use limitations Vehicle capacity Vehicle stability; Vehicle inspection and maintenance Operating limitations E Light Electric Services, Inc. 201214

15. Workplace-related topics: Hazardous (classified) locations Ramps and other sloped surfaces 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 E Light Electric Services, Inc. 201215

16. Rough Terrain Forklifts Transportable, vertical mast, reach type The vertical Mast type Variable reach (telescoping boom) E Light Electric Services, Inc. 201216

17. Protect Yourself Avoid Pinch points Avoid entanglements Avoid rotating Parts E Light Electric Services, Inc. 201217

18. Vehicle inspection and maintenance Refer to the operators manual –Each manufacture is different –Check the interval and method for air filters –Some manufactures require this be done only by an authorized technician E Light Electric Services, Inc. 201218

19. Pre-Operating Checks All instruments and gauges Horns and backup alarm Steering All controls for proper operation Brakes for proper operation Fluid levels Hydraulic leaks E Light Electric Services, Inc. 201219

20. Pre-Operating Checks Lights Safety belt Fork tilt mechanism Battery cables and connections General wiring Boom –Slide pads (extendable) Mast –lift assemble / chains E Light Electric Services, Inc. 201220

21. Pre-operations Check Forks –Cracks –Welds Fork Mount Check tires –Tire inflation effects stability Engine pre- operation checks E Light Electric Services, Inc. 201221

22. Engine or Motor Operation Rough Terrain with diesel engine –The majority of rentals in the field –Cold start problems –Lack cold cranking batteries –Lack glow plug system Solutions –If equipped plug in engine heater –Check operators manual for stating procedure E Light Electric Services, Inc. 201222

23. Engine or Motor Operation Warehouse type with propane engine Fueling / tank change out Follow instruction in operators manual Requires adequate ventilation –Propane still produces carbon monoxide E Light Electric Services, Inc. 201223

24. Differences between the truck and the automobile A car steers only from the front axle Forklifts generally steer from the back axle Rough Terrain extended boom fork lifts can steer (depending on model) –Rear steer –Front Steer –Four wheel steer –Crab Steer Check the operators manual to understand how to set or change and how to correct E Light Electric Services, Inc. 201224

25. Difference Between an Automobile and a Forklift E Light Electric Services, Inc. 201225

26. Difference Between Front and Rear Steering Rear steering provides a much shorter turning radius Rear steering also has the tail swing effect that can strike objects or personnel E Light Electric Services, Inc. 201226

27. Rear Steering Rough Terrain Fork lift with rear steering only E Light Electric Services, Inc. 201227

28. Front Wheel Steer Drives like a car E Light Electric Services, Inc. 201228

29. 4 Wheel Steer Tuning Rough Terrain Fork lift with all wheel steering Caution Tail swing Fork Swing E Light Electric Services, Inc. 201229

30. Crab Steer All four wheels angle the same way Allows for a sideways movement E Light Electric Services, Inc. 201230

31. The Problem In shifting form front steer to rear to crab to four wheel If not reset can have the wheel miss aliened for any of the steering modes Return front or rear to inline with machine Then set the other wheels to in line with the machine. Check operators manual E Light Electric Services, Inc. 201231

32. Controls and instrumentation Refer to the operators manual –Every manufacture is different –Take the time to know and understand the controls and the instrumentation –Take time to do a dry run or mock run Be familiar with the specific controls Better to practice before moving expensive materials with lead time to have shipped E Light Electric Services, Inc. 201232

33. The Work Site Avoid : – Holes – Drop-offs – Obstacles – Rough Spots – Soft Soil – Deep Mud – Standing Water – Oil Spills – Wet Spots – Slippery Surfaces E Light Electric Services, Inc. 201233

34. Know your Work Area Watch for conditions that could cause –Loss of control –A collision –Tip over E Light Electric Services, Inc. 201234

35. Know your Work Area Overhead Electrical –De-energize line if needed Hazardous weather Confined Spaces Maintain a SAFE SPEED E Light Electric Services, Inc. 201235

36. Plan Your Work Avoid Ruts and Ditches Curbs Exposed Railroad Tracks Know the Weight of the Load Use Signal person to land loads at a distance or obstructed view E Light Electric Services, Inc. 201236

37. Plan Your Work Watch for Tail and Fork swing Lower load / forks Set the parking Brake before dismounting E Light Electric Services, Inc. 201237

38. Visibility Rough terrain Forklift have large blind spots –To the rear –To the side Visibility can be blocked by the load E Light Electric Services, Inc. 201238

39. Visibility Blind spots –To the rear –To the side Know what is all the way around your forklift E Light Electric Services, Inc. 201239

40. Visibility Visibility can be blocked by the load –Operate in reverse if vision is blocked – Get a spotter to when visibility is blocked E Light Electric Services, Inc. 201240

41. Vehicle Stability E Light Electric Services, Inc. 201241

42. Stability Vehicle Center of Gravity (unloaded) Center of Gravity of Vehicle and Maximum Load (Theoretical) Stability Triangle E Light Electric Services, Inc. 201242

43. Out Side the Stability Triangle E Light Electric Services, Inc. 201243

44. Stability Triangle E Light Electric Services, Inc. 201244

45. Combined Center of Gravity When the combined center of gravity is with in the triangle the forklift is stable E Light Electric Services, Inc. 201245

46. Combined Center of Gravity When the combined center of gravity is with in the triangle the forklift is stable When the combined center of gravity is outside the triangle instability / tip over E Light Electric Services, Inc. 201246

47. Conditions that Affect Stability –Ground conditions –Speed –Grade –Load –Tire inflation –Operator skill, knowledge, judgment

48. Vehicle Capacity Know and understand load charts Posted on the machine In operators manual –With outriggers –Without outriggers –With attachments E Light Electric Services, Inc. 201248

49. Operating Limitations Center of gravity out side the stability triangle Load extended beyond load capacity E Light Electric Services, Inc. 201249

50. Stability Review: Make the Right Choice To prevent tip-overs, where should the center of gravity be in relation to the stability triangle? The stability triangle is formed by the two front wheels and the: How does adding a load affect the center of gravity? a. Inside triangle b. Outside triangle a. Operator’s seat b. Center of rear axle a. Shifts it b. Doesn’t affect E Light Electric Services, Inc. 201250

51. Basic Safety Rules Authorization Controls Alarm/horn Visibility Seat belt

52. –Don’t stand under forks –No riders –Don’t park on an incline –Don’t leave trucks unattended –Use proper shutdown Basic Safety Rules (cont.)

53. Rules of Operation Know the Load Capacity Buckle the Seat belt Lower forks flat on the ground before dismounting Never Lift personnel E Light Electric Services, Inc. 201253

54. Review Do you understand: Rough terrain forklift features? Hazards? Stability principles? Inspection procedures? Basic safety rules?

55. Operate Safely Know the weight of the Load Know the Load capacities Avoid Double stacking E Light Electric Services, Inc. 201255

56. Operate Safely Travel Slowly over rough terrain Avoid Jerks and Sudden Stops E Light Electric Services, Inc. 201256

57. Unloading from Trucks Center forks on load –Center of gravity of load Tilt load back –Lifting load by tilting Raise load for adequate clearance Retract boom or back slowly Depending on situation and type of forklift Lower load before traveling E Light Electric Services, Inc. 201257

58. Operate Safely Load positioned correctly an balanced on forks Know clearances Look for workers on the ground 360 o view Slow careful turns E Light Electric Services, Inc. 201258

59. Transporting the load Keep Forks tilted back Secure Loose loads Look Where You are Traveling E Light Electric Services, Inc. 201259

60. Safe Operations Start Slowly for stable lifts Avoid Unstable loads Place load gently and retract forks smoothly Check cracking noises that may indicate overloading Do not extend load beyond capacity E Light Electric Services, Inc. 201260

61. Operate Safely Have Adequate Clearance for fork and tail swing Keep loads low E Light Electric Services, Inc. 201261

62. Transporting the load DO NOT travel with the boom UP across a slope Traveling with no load / forks pointed down (counter weight / most weight UP) Traveling with a load / forks pointed uphill (The most weight Up ) E Light Electric Services, Inc. 201262

63. Surface Loading Know Landing Weight limits DRIVE as close as possible to landing Set parking brake before lifting load KEEP loads level E Light Electric Services, Inc. 201263

64. Forklift Damage Never load the fork lift with a twist force on the boom This can damage the machine Leaving dangerous hidden damage –In the boom structure –In the boom guides and slides –In the pins and bushing of the machine E Light Electric Services, Inc. 201264

65. Check weight charts Set forks Slide forks Center load Tilt mast Lift load Check weight charts Set forks Slide forks Center load Tilt mast Lift load Loading

66. Weight Collisions Speed Edges Load too high Sudden turning or braking Load tilted too far forward Causes of Tip-overs

67. Preventing Tip-overs –Load capacity –Turns –Inclines –Load position –Ground conditions –Braking

68. Exercise Which are possible causes of a tip-over? –Exceeding load capacity –Center of gravity inside stability triangle –Excessive speed when turning –Traveling with load raised too high –Tilting load back while traveling –Braking suddenly with load raised E Light Electric Services, Inc. 201268

69. In the Event of a Tip-over Never Jump Stay seated Keep seat belt on Keep arms and legs inside the ROPS –(roll over protection structure) Brace your self in a tip over Lean Away from the Impact Shut the engine off Immediately E Light Electric Services, Inc. 201269

70. Review Do you understand: –Safety procedures for loading and unloading? –Traveling safely? –Causes of tip-overs? –Preventing tip-overs? –What to do in the event of a tip-over?

71. Key Points to Remember Know the hazards Know how to be safe Understand stability principles Never operate unless you are authorized E Light Electric Services, Inc. 201271