HEAVY EQUIPMENT

OPERATION
Forklift
 Forklift
• a vehicle with a pronged device in front for lifting and
carrying heavy loads.
– Purpose is to move, carry, push, pull and lift
material load then stack it or place in a storage
rack
– Loading and unloading of materials from delivery
containers
 Selection of capacity
based on job requirements

– Where will my forklift be used?

– Type of load
– Load weight
– Lift height
– Aisle clearance
 Forklift Selection
• OSHA Forklift Classification
– Class I: Electric motor rider trucks
– Class II: Electric motor narrow aisle trucks
– Class III: Electric motor hand trucks or hand/rider trucks
– Class IV: Internal combustion engine trucks (solid/cushion
tires)
– Class V: Internal combustion engine trucks (pneumatic tires)
– Class VI: Electric and internal combustion engine tractors
– Class VII: Rough terrain forklift trucks
 Class I:
Electric motor rider trucks
• Counterbalanced Rider • Three Wheel Truck, Sit
Type, Stand up down
 Class I:
Electric motor rider trucks
• Counterbalanced Rider, • Counterbalanced rider,
cushion tires, sit down either pneumatic or solid
type tires, sit down
 Class II:
Electric motor narrow aisle trucks
 Class III:
Pallet Jack
 Class IV:
Internal Combustion Engine
 Class V:
Internal Combustion Engine
 Class VI:
Electric & IC Engine Tractors
 Class VII:
Rough Terrain Forklift Trucks
Forklift Basic Parts
Types of Forks
Visual Checking (engine off)
• Check OS parts / standards*
– Equipment operator serviceable parts
• Perform walk around check while engine is
not running
– 360
• Perform BLOWAF check
– Actual component checking (engine off)
 Operator Serviceable Parts
Coolant Reservoir

Radiator
 Operator Serviceable Parts

Brake Fluid Reservoir

 Operator Serviceable Parts

LPG Tank / Fuel Tank

Battery
Operator Serviceable Parts
Hydraulic Hose
Visual Checking (engine off)
• Perform walk around check while engine is not running
– 360°
• Fill out checklist
– Leaks
– Fluid levels
– Worn out / Damaged parts
– Loose parts
– Missing parts
– Tire condition
Visual Checking (engine off)
Perform T.H.E.B.L.O.W.A.F.S.S. (performed with checklist form and
engine not running)

T – Tire (condition & air pressure)

H – Horn (front & backing-up)
E – Engine (Leaks)
B – Battery charging and starting
L – Lighting system
O – Oil (lubricating system)
W – water (cooling system)
A – Air (intake and exhaust)
F – Fuel system
S – Self
S – Safety (PPE & truck accessories)
B.L.O.W.A.F.
• Deficiencies in fluid levels are identified and refilled as
needed:
– Battery solution
– Engine oil (15W-40)
– Hydraulic oil (VG 68)
– Radiator coolant
– Brake fluid
– ATF / transmission fluid
– Fuel
– Gear oil
 Visual Checking
(engine running)

• Perform starting / running check

– Actual component checking
• Perform visual check for lifting attachments and power
train components
• Perform operation check
– Actual checking of attachments
• Perform post operation procedures
– 360°
 Visual Checking
(Engine Running)

• Gauges
• Oil and air leaks
• Safety devices
• Working equipment
• Unusual sound
• Unusual emission / smoke
 Visual Checking
(Engine Running)

• OSHA standard safety devices checked for proper function

– Horn
– Back-up alarm
– Seatbelt
– Side mirrors
– Fire extinguisher
– Parking brake
– Blinkers / beacon light
 Visual Checking
(Engine Running)
• Perform visual check for lifting attachments and power train components
• Perform operation check
– Lift control
– Tilt control
– Directional control
• Gauges
– Battery charging
– Engine oil pressure
– Hydraulic oil pressure
– Engine temperature
– RPM
– Hour meter
– Fuel
Perform Post Operation
Check
 Perform Post Operation
Check

• Safety locks are checked

• Steering lock
• Parking brake
• Engine compartment
lock

• After operation
• Perform another 360°
 Perform Productive
Operation

• Know all safety devices and functions

• Mount and dismount correctly
• Perform pre-operational inspection
• Never operate a forklift in need of a repair
• Never operate forklift for any purpose other than
what it was designed for
Forklift operation
• Load chart interpretation
– Lifting principles
– Following lifting capacity
• Lift and transfer loads
– Forklift operation and safe lifting
Lift Classification & Rated Load Capacity

• The maximum amount of weight that

can be safely lifted.
• Pre-lift testing
– Operator should lift the load one or
two inches and make sure the
equipment is firm and stable
Nameplate & Rated Load Capacity
Lifting Principles
Stability Triangle
What can cause a tip over?
Stability Triangle

• Center of gravity side

to side
• Center of gravity
forward
• Center of gravity
backward
Stability Triangle

• Moving center of gravity

outside stability pyramid:
• Loss of steering
• Loss of traction
• Unstable load
• Potential for a tip over
• Potential for a tip up
Stability Triangle
Stability Triangle
• The forklift will not
tipover as long as the
Combined Center of
Gravity of the truck and
load system remains
within the Stability
Triangle.

• If the CG shifts outside the

boundaries of the stability
triangle, the truck will
tipover.
Stability Triangle
Fulcrum Principle
Fulcrum Principle
Forklift Operation & Safe Lifting
• Travel & Maneuver
– Mounting & Dismounting
– Starting/Stopping
– Operating at speed
– Steering, turning & changing direction
– Traveling on inclines
– Parking
– Safe travel practices
– Visibility
– Tipover
Travel and Maneuver

Mounting
and
Dismounting
Starting & Stopping
• Before starting a forklift, be sure to
conduct a pre-operation inspection. In
addition, conduct an operational check
after starting the engine.
• After parking, proceed with post
operation check up
 Operating at Speed & Safe Travel Practices
• Under all travel conditions the truck must operate at a speed that will permit it
to be brought to a stop in a safe manner.
• The driver must slow down for wet and slippery floors.
• The driver must look in the direction of, and keep a clear view of, the path of
travel.
• The driver must slow down and sound the horn at cross aisles and other
locations where vision is obstructed. If the load being carried obstructs forward
view, the driver shall be required to travel with the load trailing.
• While negotiating turns, speed shall be reduced to a safe level by turning the
steering wheel in a smooth, sweeping motion.
• Grades shall be ascended or descended slowly.
• When ascending or descending grades in excess of 10 percent, loaded trucks
shall be driven with the load upgrade.
• Running over loose objects on the roadway surface shall be avoided.
Steering, Turning & Changing Direction

• Turning & Steering Potential Hazards

– Collision with pedestrians or objects
due to the forklift's tail swinging to the
side opposite the direction of the turn.
– Falling load following collision.
– Tipover caused by turning too sharply.
Steering, Turning & Changing Direction

• Changing Direction Potential Hazards

– Tip over.
– Collision with a pedestrian, another
vehicle or an object.
Steering, Turning & Changing Direction

• Reversing Potential Hazards

– Pedestrians being struck by or
crushed by the forklift.
– Collision with another forklift or
racking.
Steering, Turning & Changing Direction
Steering, Turning & Changing Direction
Steering, Turning & Changing Direction
Traveling on Inclines
Traveling on Inclines
Traveling on Inclines
Traveling on Inclines
Parking
• Potential Hazards While Parking and
Leaving the Forklift Unattended
– Danger of an improperly parked
truck being struck by personnel or
objects.
– Danger of unintended movement of
the truck.
Visibility
Visibility
Tipover
 Lift and Transfer Loads
• Safe handling preparation
• Approaching
• Mast position
• Fork position
• Lifting the load
• Lowering the load
• High tiering
• Truck trailers and railroad cars
 Safe Handling Preparation
• Potential Hazards
– Off-center loads which
may cause tipover or
falling loads.
– Overloading which
may cause tipover or
falling loads.
– Damaged or loose
loads.
Approaching
Mast Position
Forklift Position
Lifting The Load
Lowering the Load
High Tiering
• Set the heaviest loads on the bottom tier.
• Set the lightest loads on the top tier.
• Reduce the load below the capacity of the
reach truck as the mast is fully extended.
• Slowly and carefully extend the reach
mechanism forward when depositing the load
on the top tier.
• Use extreme care when tilting a load forward or
backward, particularly when high tiering.
Trailer Operations
• Ensure the trailer floor is rated for the vehicle weight
• Verify that the trailer floor is in serviceable condition
• Ensure the forklift will not unbalance the trailer
• Use additional trailer support if unbalancing is a risk
• Consider the interior trailer height
• Ensure the trailer cannot roll away from the dock
• Consider lighting and inclement weather
Safety Tips!
• Pedestrians have the right of way
• Look in the direction of travel
• Forks shoud be 4 to 6 inches above ground level
if terrain permits
• Mast should be angled slightly backwards
• Slow down and sound horn when approaching
blind corners
• Drive in reverse if your forward vision is
obstructed
Safety Tips!
• Never stand under a raised load
• Always move slowly when the load is raised
• When stacking, ensure that the load is level
and secure
• Stack round objects tightly together and
place chock or block
• Be careful when backing out of a load where
a pedestrian is in your pathway
 Forklift Basic Repair
• Perform adjustment or replacement for noted
defects
– Minor operator serviceable parts
– Major defects
• Perform basic preventive maintenance servicing
(PMS)
– Minor preventive maintenance for O.S. parts
 Forklift Basic Repair
Perform Adjustment and Replacement
• Minor defects are identified and fixed
– Weak battery
– Belt tension
– Clogged air cleaner
– Loose battery terminals / connection
– Tire inflation
– Busted lights
 Forklift Basic Repair
Perform Adjustment and Replacement
• Correct / proper tools are selected and used based on job requirement
– Adjustable wrench
– Ballpeen hammer
– Screw drivers
– Pliers
– Combination wrenches
– Steel brush
– Vice grips
– Grease gun
 Forklift Basic Repair
Perform Adjustment and Replacement
• Major defects and identified with checklist & referred to
appropriate personnel
– Abnormal tire wear
– Unusual smoke
– Excessive oil consumption
– Hard starting
– Faulty gauges
– Abnormal engine sound
– Damaged underchassis
 Forklift Basic Repair
Perform Adjustment and Replacement
• Major defects and identified with checklist & referred to
appropriate personnel
– Leakage in
• Hydraulic system
• Lubricating system
• Cooling system
• Fuel system
– Damage carriage parts (fork, mast, hydraulic hoses and
cylinders)
 Forklift Basic Repair
Perform Adjustment and Replacement
• Major defects and identified with checklist & referred
to appropriate personnel

• Appropriate personnel
– Chief mechanic
– Equipment maintenance supervisor
– Maintenance personnel / electrician
 Perform Basic Preventive
Maintenance
• Operator serviceable (O.S.) parts are identified and serviced
– Air cleaner
– Battery terminal conditions
– Fan belts / drive belts
– Tire inflation
– Grease lube points
– Fuel water separator
– Mast chains
 Perform Basic Preventive
Maintenance
• Fluids and lubricants are used according to manufacturers standards
– Engine oil 15w-40 (SAE 40)
– Hydraulic oil VG68 (SAE 10)
– Multi purpose grease
– Radiator coolant
– Battery solution
– Transmission fluid (ATF)
– Brake fluid
– Gear oil (SAE 90)
– Fuel (LPG, gas, diesel)
 Perform Basic Preventive
Maintenance

• Basic preventive maintenance servicing (PMS) is

carried out according to standards
• Basic PMS
– Check battery clamps
– Check fan belt condition
– Clean / replace air, fuel and oil filters
– Replace defective fluid caps
– Grease all lube points
Basic Hand Signals
Sample Equipment Checklist
Sample Equipment Utilization Form
Thank You!