英语学习]SafeForkliftOperationsOperatorCertificationrev.ppt

SAFE FORKLIFT OPERATIONS & OPERATOR CERTIFICATION,Prepared by Riyad Al-Darawish,FORKLIFT OPERATIONS AND USE,Section 1 The Care & Maintenance of Powered Industrial Trucks Truck Operators Responsibilities,Section 2 General Safety Precautions,Section 3 Walk Around Inspection,Section 4 General Rules for Operation of Powered Industrial Trucks All Types,Section 5 Rules for Operation and Changing Batteries,THE CARE & MAINTENANCE OF POWERED INDUSTRIAL TRUCKS. TRUCK OPERATORS RESPONSIBILITIES,SECTION 1,FORKLIFT OPERATION AND USE,INTRODUCTION,The efficiency and safety in the use of forklifts and other equipments depend mainly on the competence of those who control, maintain and operate the equipment.,Operators must be trained in all aspects of forklift operations. This safety training will provide you with a sound knowledge of the safety requirements which you will be expected to observe during all forklift operations. If at any lime you wish to ask questions, make it known and we will endeavor to answer them.,RECORDS,All forklift trucks need to be regularly maintained and records are kept for this purpose to assist the plant manager and mechanics. It is your responsibility to report any defect observed during your daily routine inspection. Spare parts may take time to be delivered, so report faults immediately. During your daily routine inspection, it is your responsibility to report any defect observed to your immediate supervisor and plant management. By reporting defects early, you assist plant management in ordering parts which may have a long delivery period.,LIVE.,TIME,MONEY,and most important,MAINTENANCE,Plant supervision will have a manufacturers manual of all mobile & static plant including forklift so they can regularly maintain equipment to eliminate any potential fault and allow safe operation. This is sometimes a complex job which requires the TIME of a profession. The driver can assist by regularly checking the following:,1. Check any defects previously reported to immediate superior.,2. Check Battery level.,3. Check tyres for wear, damage pressure.,4. Check fork retaining pins,5. Check water and oil level,6. Check brakes,12. Check lift and tilt system.,7. Check steering.,8. Check horn, reversing alarms,9. Check lights, mirrors etc.,Check working of lift mechanism for lubrication or damage to hydraulic hoses.,11. Check load chains.,MAINTENANCE,STACKING OF MATERIALS,Stacking areas should be clearly designated and built on firm level ground with good drainage. There should be adequate clearance between the stack and any wall, walls have been known to collapse with vertical pressure.,Stacked cylindrical material should be choked to prevent rolling and eventual collapse.,Drainage rings should never be positioned on their side but laid flat.,THE STABILITY OF THE STACK DEPENDS ON:,The relation of its height to narrowest base dimension (height should not exceed three times narrowest base width),Interlocking of material to prevent movement.,Proper understanding of weight to be carried by the components at the bottom of the stack. i.e. stocking heavy goods on light packages is not a safe practice and can cause severe damage.,When removing a stack do so in reverse order. Stop at face of stack and raise load to stacking height, still tilted back. Move load over stock, bring mast to vertical, lower until forks are free of load Withdraw and lower forks just clear of floor before traveling away.,MACHINE STABILITY AND SAFE LOAD LANDING,Safety in all forklift operations requires machine stability at all times. The rated capacity of a machine will be given by the manufacturer. However always investigate that the capacity is appropriate for the work to be done. Remember that stated capacities apply in a static condition and may be far in excess when the machine is moving. Limits of safe operation will depend on ground conditions and, as far as possible machines should be operated only on designated routes.,OFF LOADING TRUCKS,All material used on site arrives on some form of road transport and it is important that a firm level area is designated as the unloading point. This area should be quite separate from the material storage area and sufficiently spacious to allow forklift access to both sides of the lorry for unloading.,A signaler, usually the lorry driver, should guide the forklift operator in the unloading and particular regard should be paid to:,The sequence for unloading; for example the vehicle could be dangerously out of balance if all the material were to be removed from one side of the vehicle.,The instability of the loads, (e.g. cylindrical items) resulting from insecurity due to the removal of chains, ropes etc,Avoiding fouling adjacent loads, e.g. with the fork tips protruding past the load being removed.,Where trucks need to be loaded or off-loaded Off-site and there is a possible risk to the public or other road users, then warning cones, barriers etc. should be erected preventing access.,Raising the load clear of the vehicle platform, reversing away from the vehicle, lowering the load to a safe distance above ground level before transporting it to the storage area.,HANDLING AWKWARD LOADS,Those loads of irregular shape, for example scaffold tubes, drill pipe and instrument valves, demand extra precaution in their handling and movements by forklifts: They must be lifted and positioned on the forks at their centre of gravity. If this is not readily apparent, trial loading should be carried out until the point of balance is verified. The items should be tied together to form an integral load. The load should be positioned against the heel of the forks, and tightly secured in place. A signaler should be employed as necessary to ensure that the load remains stable throughout the transit.,SAFETY DEVICES ON ROUGH TERRAIN FORK LIFTS,Rough terrain forklifts should have safety devices incorporated in its hydraulic system which shall not allow forklifts to lift weights greater than its rated load. It must also have a device which will prevent a specified load being lifted beyond a given height.,The provision of a leveling indicator is strongly recommended.,All telescopic material handlers should be fitted with an automatic safe load indicator (SU). which gives a continuous read out of forward stability and sounds an audible alarm when load exceeds 95% of the safe working load. Other safety devices which should be filled to rough terrain forklifts are:,Leveling Indicator,Check-Valves which will hold the load in the event of hydraulic pressure loss.,An indicator lamp which will show when stabilizers are on fully extended and engaged on firm ground.,SAFETY OF SITE PERSONNEL,Every one not directly involved in forklift operations should keep well clear of the machine. 2. The carrying of passengers on a forklift truck is forbidden. Persons acting as banks men, or guiding the driver should: a. Keep a safe distance from machine and its load. b. Never stand under an elevated load. c. Wear conspicuous clothing and keep within the vision of the driver. Reflective jackets must be worn during poor visibility. d. An overhead guard shall be used as protection against falling objects, however this guard should not interfere with drivers visibility,SCAFFOLD LOADING WITH A FORKLIFT TRUCK,Before any load can be put on a scaffold, you must check with the scaffold foreman that the scaffold design is for heavy duty or capable of withstanding the load. Ensure loads are placed on designated loading points.,Any handrails or toeboards removed to gain access must be replaced. Care should be taken not to give much pressure on the scaffolds with the forks.,ATTACHMENTS,Attachments are designed to increase the scope of forklifts. In each case, it must be remembered that the use of any attachment can radically alter the forklift stability and its safety.,Any attachment should preferably be made by the manufacturer and Its installment done in consultation with them. Should this not be the case, then the attachment should be designed by a competent person and adequate testing carried out prior to general use.,INDUCED FORCES,When operating forklifts, drivers must be aware of the machines stability with regard to induced forces. These are forces which act upon a machine or its load due to a change in speed or direction; for instance when starting, stopping, turning or rolling. The greater the speed of the machine, the greater these induced forces, accelerating, decelerating and braking must be done progressively and smoothly, never hard or jerkily. Turning must be done carefully giving due consideration to the weight and placing of the load and the condition of the ground.,WITHIN LOAD CENTRE STABLE,OVERHEAD CABLES,On construction sites where overhead cables are located (or where they are likely to be installed) the clearance margin requirements of the Electricity board, and the appropriate statutory requirements (e.g. Goal posts) must be observed at alt times.,GENERAL SAFETY PRECAUTIONS,Qualified and Trained personnel shall only operate the forklift trucks.,Forklift trucks must not be left unattended without shutting off the engine.,3. The hand brake must be applied when parked and while lifting or lowering.,4. Always keep the forks in the lowest position when traveling or when parked.,5. Engines should be stopped before refueling.,15. Travel at a sale speed.,6. Never transport chemicals, oils or flammable material in open containers.,7. Never lift with only one fork unless it is specially designed for the operation.,8. When picking up or stocking a pullet, ensure the forks have not engaged any other pallet or objects.,9. Never allow anyone to walk under elevated forks.,10. Do not put arms or legs between mast upright.,11. Beware of overhead obstructions.,12. Descend slopes with load behind you.,13. Drive uphill with load in front of you.,14. Keep loads secure and fully tilted back.,If you as the operator conform to all of the general safety instructions, then you should have a trouble free operation.,For maintenance and operation personnel safety, and maximum service life of the lift truck, make a thorough walk-around Inspection, looking for such items as loose or missing bolts, oil or coolant leaks, wear and damage to Mast and Fork carrier, cut or gouged tires etc.,WALK AROUND INSPECTION,GENERAL,1. Check tyres for wear or damage,2. Check tyre inflation,3. Check vehicle structure for cracks, distortion, damage,4. Check for loose or thread damaged nuts and bolts, loose rivets / pins or missing locking devices,5. Observe condition of Fork Truck maintenance,CAB,1. Check for defective gauges,2. Make sure all operating levers and switches are clearly marked,3. Check if correct duty chart is fitted,4. Check for loose or damaged parts,5. Make sure the fire extinguisher is secured correctly and fully charged,6. Make sure there are no loose tools in the cab,7. Make sure that all cab glass is in good condition,8. Make sure that all safety Decals are fixed in their correct positions,CONTROLS 1. Check all control levers are clearly marked 2. Check for excessive wear on lever linkages 3. Make sure all controls operate correctly,GAUGES,1. Check all gauges for correct function.,WARNING DEVICES,Check that the Safe Load Indicator is functioning correctly (where fitted). 2. Check Roto Flash Beacon 3. Check all audible alarms operate normally,ENGINE VISUAL INSPECTION,Start engine and idle until operating temperature is reached. Once achieved, stop engine and inspect for the following:,1. Oil Level 2. Oil Leaks 3. Leaking Gaskets (e.g. Inlet/Exhaust, Cylinder Head, Sump etc.) 4. Loose Nuts and Bolts 5. Cooling Fan (where fitted) for Damage to Blades 6. Drive Belts and Pulleys for Wear/Damage 7. Hoses and Pipe work for Leaks or Damage,EXHAUST SYSTEM 1. Visually inspect the following: 2. Make sure there are no leaks or holes at pipe joints or flanges 3. Securing brackets or clamps for tightness 4. Inspect silencers for holes or excessive corrosion 5. Make sure spark arrestors (where fitted) are in good order and functioning correctly,AIR FILTER Visually inspect the following: 1.Filter housing for signs of damage 2.Securing brackets for tightness 3.Hoses and clips for signs of damage or wear 4.Filter element for cleanliness,Visually inspect the following: 1.Check for damage, corrosion and cracked welds,CHASSIS,TRANSMISSION/ DRIVE TRAIN,Check for the following:,1. Oil leaks,2. Loose or missing bolts/nuts,* 3. Excessive play in universal joints,* 4. Excessive noise from diff carrier and transfer box,* 5. Correct operation of gear box and torque convertor,* - For Mechanics,STEERING, BRAKES & SUSPENSION,Check for the following:,1. Correct operation of both Foot and Hand brakes 2. Leaking steering cylinders and damaged flexible hoses 3. Loose or worn tie rods 4. Loose or missing wheel nuts/studs 5. Worn ball joints 6. Broken leaf springs (where applicable) 7. Leaking shock absorbers 8. Torn or missing gaiters. 9. Worn or defective wheel bearings 10. Worn or damaged tyres,STEERING AXLE,1. Spindle 2. Axle Frame 3. Steering Cylinder,LOAD CHAIN,1. Check load chain for wear and cracked links 2. Check The load chain anchors for correct installation 3. Check load chain for correct tension,LOAD ROLLERS,1. Check rollers for flats 2. Make sure all rollers are free to turn,MAST,1. Check mast sections for distortion 2. Check the mast for cracked welds and loose bolts,HYDRAULIC CYLINDER,1. Check for oil leaks around the ram seals 2. Check all link pins for wear 3. Check the hoist and tilt cylinders for creeping under the load,3. Check the forks for cracks and distortion 4. Check all lock pins for correct function and ease of operation,FORKS AND CARRIER,MEASURING CHAIN WEAR,Clean the upright weldments with steam or solvent. Inspect the sliding and rolling surfaces. Inspect the welds around the stub shafts.,! WARNING,DO NOT weld on uprights. Get information from your fork truck dealer before welding.,Examine the chain pins to determine if they extend outside of their of their bores. If pins are extended too much, it is indication that they are broken. Replace if necessary. Broken chains can cause personal injury,! WARNING,CHAIN WEAR,1. Worn Pin,2. Cracks,3. 5% Edge wear,4. Hole wear,5. Looseness,6. Pin Wear,7. Corrosion,TYPICAL VISTA TWO-STAGE UPRIGHT,HOOK AND PIN FORKS,HYDRAULIC/PNEUMATIC SYSTEM,Check Hydraulic oil level oil level. 2. Check Hydraulic oil tank for ruptured seams, external damage or leaks. 3. Check for leaks (Seals, Glands, Unions & hoses). 4. Check for damaged deteriorated flexible Hoses. 5. Check cylinders/ rams for misalignment, wear & scoring. 6. Check anchorage pins & their fasteners. 7. Check for correct operation of relief valves (where possible). 8. Check all operating pressures (REF. TO MANUF SPEC).,ELECTRICAL SYSTEM,Check battery condition, electrolyte level etc. 2. Check that there are no broken or loose wires. Ensure all lights operate correctly. Ensure all audible alarms operate normally. 5. Ensure all limits operate correctly.,STEERING BRADGES & SUSPENSION,Check for the following:,Correct operation of both foot & hand brakes. 2. Leaking steering cylinders & damaged flexible hoses. 3. Loose or worn tie rods. 4. Worn ball joints. 5. Loose or missing wheel nuts/ studs. 6. Broken leaf springs (where applicable). 7. Leaking shock absorbers. 8. Torn or missing gaiters. 9. Worn or defective wheel bearings. 10. Worn or damaged tires.,GENERAL RULES FOR OPERATION OF POWERED INDUSTRIAL TRUCKS (ALL TYPES),Do not operate any truck unless you are properly trained and authorized for that particular type of truck.,2. At the commencement of each shift or whenever you take charge of the truck from someone else, ensure that the horn, lights, brakes, tyres, steering, lift mechanism, particularly chains and fork arms, and all controls are in good working order.,Verify, if applicable, that the mirrors are set and the windows are clean, and in the case of pneumatic tyred trucks, that the tyre pressures arc correct. Check for oil leaks, the state of the battery arid all fluid levels. Remove any loose articles left on the truck. Report all defects immediately to your supervisor. N. B.: Whenever “fork arms are referred to in the text, this, when appropriate, shall also be taken to mean an attachment or other equipment fitted to the carrier in place of fork arms.,3. Ensure that your truck is the correct type for the area you are to work in. Dont enter a hazardous zone with an unsuitable truck.,4. Comply with instructions concerning floor loadings.,5. Face the truck when mounting or dismounting from the cab and use the steps and handles provided.,6. Take care when you see this symbol It means: ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED,7. Carry loads as near to the ground as practicable.,8. LOOK in the direction of travel BEFORE and while traveling and keep a clear view of the way ahead.,9. If a bulky load obscures forward vision, drive in reverse. However, the load should lead when traveling up inclines and, if vision is obscured, the operator should seek assistance. See also rules 48 and 49.,10. Ensure that any place where a load is to be set down is strong enough to accommodate the. weight of the load.,11. Do not carry divisible loads that are higher than the fork carriage or backrest extension.,12. Do not remove a back rest extension or overhead guard, nor fit or use an attachment unless specifically authorized.,13. Drive at a speed consistent with conditions. Slow down for wet, slippery or loose surfaces.,14. Do not run over loose objects. Stop the truck, remove objects (dunnage, etc.) to the side and report to the supervisor.,15. Keep a safe braking distance from any vehicle in front. Remember that some when laden, especially in reverse. Do not overtake when approaching aisle or road crossings, junctions, nor in blind area