Namib Mills Forklift Training

Index:

Module 1: Getting to know your Lift Truck (Forklift)

Module 2: Physics of a Lift Truck ( Forklift )

Module 3: Operating a Lift Truck (Forklift)

Module 4: Lift Truck (Forklift) Safety

Module 5: Maintenance

Module 6: Re-Fuelling and Re-charging

Module 1: Getting to know your Lift Truck
(Forklift)
There are four basic types of lift trucks at Namib Mills:
1. Diesel powered
2. Electric powered
3. Gasoline powered
4. LP-Gas powered

Different types of environments require different types of lift trucks. Check with
your supervisor or safety office to confirm that you are using the correct type of lift
truck for your work area.

The modern lift truck is an amazing piece of machinery. Did you know that lift
trucks:
* Often weigh more than a car or light truck.
* Are extremely powerful.
* Use rear wheel steering.
* Can turn in a tighter circle than most vehicles.
* They are often less than 1,5m wide.
Let's take a few moments to look more closely at the major parts of a lift
truck.
 Engine Hour Meter

The Engine Hour Meter records the total number of hours that an engine
has been used. Because this information is used to schedule maintenance,
you will need to record this number on your Daily Checklist (Appendix B in
your Manual).
Different Indication Gauges on a Forklift.

The Fuel Gauge indicates the fuel level and is

similar to those found in cars and trucks. "F"
means full, while "E" means empty. Always check
the fuel level of your lift truck during your daily
inspection.
The Amperes Gauge indicates that the engine's
electrical generator is producing electricity. (+)
readings mean the generator is working. (-) readings
mean something is wrong, and that battery power is
being used to run the engine. Always return a lift
truck for maintenance, if the amperes gauge is
showing (-) readings.

The Oil Pressure Gauge indicates the oil pressure

inside the engine. Oil pressure readings that are
low or drop to "0" indicate that there is a serious
problem with the engine. Never operate a lift
truck with oil pressure problems. Turn the engine
off, and notify your supervisor or the
maintenance department.
Electric powered trucks have a Battery Capacity
Gauge, instead of a fuel gauge.
The Steering Wheel in an industrial truck
operates like one in a car or truck.

Most trucks are equipped with a Directional

Control, which allows you to select to move
the truck forward or backward.

All trucks have an Accelerator pedal and a

Brake pedal. Some trucks have a Clutch, which
allows shifting into higher forward gears.
 Electric powered trucks have an accelerator
pedal and a brake pedal.

All trucks are equipped with a Parking Brake. You should always set
the parking brake whenever you leave a truck.

All trucks are equipped with two basic

hydraulic lift controls.
The Raise and Lower Control allows you to
raise the forks up or lower the forks down. Pull
the lever back, and the forks will go up. Push
the lever forward, and the forks will go down.

The Tilt Control allows you to tilt the forks up

or down. Push the lever forward, and the forks
will tilt down. Pull the lever back, and the forks
will tilt up.

Trucks are equipped with a horn to sound

warnings to others who may be in your
operating area.

Ignition or Turn On / Off switch. Most industrial

trucks require that a key be used to start and
turn off the truck.
All industrial trucks have a Data Plate attached to the
truck body. Data plates display important information
concerning the truck's:

- Type
- Capacity
- Load Centre
- Truck Weight

Read and remember the data for the trucks you

operate.
 At Namib Mills we use the following tires.

Solid tires are Pneumatic tires (tires

designed for use filled with air) are
inside on smooth, dry designed for use on
surfaces. They should improved surfaces, and
not be used outdoors may be used outdoors,
or on rough surfaces. as well as indoors.

Tires, like industrial trucks, are designed for specific types of jobs. Alw ays
check to make sure you are using the right type of equipment for each job.

The lifting system on lift trucks includes chains

attached to a hydraulic cylinder.
The Three major parts of the lifting system.

When the cylinder is filled with hydraulic fluid, it

forces the piston to move upward.

The upward movement of the piston and the

chains lift the forks to the desired level.

The lifting forks on your lift truck can be moved from

side to side to adjust for different types of loads.
While most lift trucks require that this be done by
hand, some have special controls for adjusting the
forks.
Module 2 : Physics of a Lift Truck ( Forklift )

Unlike a car or truck, lift trucks use the rear

wheels for steering.
 Stability Triangle

If you were to raise a lift truck up and look at its underside, you
would see that the support points for the truck are located at
points A, B, and C. The triangle formed between points A, B,
and C is called the Stability Triangle. The lift truck will not tip
over as long as the centre of gravity remains inside the triangle.
(The centre of gravity is the point within a lift truck where there
is equal weight all around it.)

The centre of gravity within a lift truck can only be moved

by:
• Traveling with an elevated load;
• Trying to carry too heavy a load;
• Trying to turn the lift truck while it is moving too fast;
• Operating the lift truck on a hill or incline;
• Starting or stopping too fast;
• The jerky operation of the hydraulic system.
 Load Capacity

The front wheels of a lift truck serve as the Fulcrum Point (the centre point by
which an object will turn on) between the weight of the truck and the weight of
the load being carried.

If the weight of the load is equal to the weight of the truck, with equal distances
between the centres of gravity, it is possible to "seesaw" a lift truck on its front
wheels.
If we rearrange the load so that the load's centre of gravity is further away
from the fulcrum point, this will cause the centre of gravity for both the
truck and the load to shift beyond the front wheels of the truck, and the
truck will tip forward.
If, on the other hand, we arrange the load so that the load's centre of gravity
is closer to the fulcrum point, this will cause the centre of gravity for both the
truck and the load to shift behind the front wheels of the truck. With this
arrangement, there is no danger of the truck tipping forward.
Your most immediate source of information
concerning the safe load capacity of a truck can be
found on its data plate.

The plate will give you information concerning the

load capacity of the truck in kilograms and the load
centre in Millimetres.

The lifting capacity described on this plate is 3200

kilograms with an LC of 24 Millimetres, up to a height
of 188 Millimetres from the floor.

Never exceed the load capacity.

 Load Centring

When lifting and carrying several loads at once, always place the heaviest
load against the back of the forks.

Placing the heaviest loads near the back of the forks shifts the load centre
closer to the front wheels and makes for a more stable load.
You can increase the stability of a load by tilting the forks back.

Tilting the forks back moves the load centre closer to the front
wheels.
On the other hand, tilting the forks forward shifts the load
centre away from the front wheels and creates a less
stable load, especially when the forks are raised. You
should never tilt the forks forward when they are raised,
except to deposit a load.
Module 3: Operating a Lift Truck (Forklift)

Keep in mind that you are operating a lift truck, not a race car or jet
fighter.

In case of an accident, you don't have an ejection seat.

Always start and stop smoothly, and KEEP YOUR SPEED DOWN!
The higher you lift a load, the more unstable it
becomes. Always take extra care when making
sharp turns with a raised load.

The 8 Inch Rule (20cm)

When transporting loads, you should never

raise your load more than 8 inches (20cm)
from the ground. Keep your load tilted back.
If a load blocks your view, travel in reverse.

There are times when you need to move your

truck with a raised load, such as when you
are right angle stacking. SLOW DOWN. Keep
in mind that the higher you raise your load,
the less stable it is.
As you lift and transport loads, it is
important to watch for overhead
obstructions such as beams and cables.

Chain slack means there is a problem in

the lift mechanism. You should always
stay alert to any problems with the lift
mechanism of your lift truck. When
problems do occur, DO NOT ATTEMPT to
repair the chains or hydraulic system.
Call maintenance at once.
Take time to adjust the forks on your lift to fit the
load you will be carrying. Adjusting the forks
outward for wide loads, helps you to centre the
load, and make it more stable.

Never try to lift or carry loose or

poorly stacked loads. Correctly stack
and bind loads to prevent an accident
that could damage the load, your
truck, pedestrians or YOURSELF.
Wide and long loads are more unstable than other loads. Wide loads require
that you keep them low and watch the balance of the load. When lifting and
carrying long loads, keep in mind the load centre and lift capacity of your
truck. With both wide and long loads, you will need more room to manoeuvre.
So, slow down and watch your clearance.
 If you are driving an empty truck, travel in reverse up an incline, and
forward down an incline. Note that the centre of gravity for the truck is
above the front drive wheels.

NEVER turn while driving up or down a ramp or

incline. NEVER drive across a ramp or incline.
Because lift trucks are built " narrow," the centre of
gravity can quickly shift outside the stability
triangle, causing the truck to tip over.
Ice, mud, gravel, sand, and soft dirt all present potential problems for
you and your lift truck. Avoid these unsafe surfaces, if at all possible.
They can damage your lift truck or cause an accident.
 When crossing an uneven surface you need to
slow down and asses the surface first. If it
cannot be avoided, then cross with one wheel
at a time at an angle. Watch out for potholes
and floor surfaces that may have more than
one level.

Keep in mind that you are operating a piece of

HEAVY equipment. Check with your supervisor
to make sure that you are operating your lift
truck in areas that will support both the truck
and the load.

Always know the maximum weight capacity of

elevators and lifts before you use them. Don't
forget to calculate the total weight of your
truck and your load before entering an
elevator.
Loading docks can be dangerous places. Always be aware of the edge of the dock. A fall
from a loading dock in a lift truck can be fatal. Slow down, watch out for others, and live.

1.Inspect the floor of the trailer to ensure that

it will support the lift truck and the load.

2.Make sure that the wheels of

the trailer are chocked to
prevent the trailer from moving.

3.Make sure that dock plates, boards, and

ramps are in place and secure.
 You are responsible for your truck, even when you leave or park it.

Always lower the forks until

Never leave or park your lift truck on they are flat on the floor.
Always park your truck in a
an incline.
safe area that is away from
traffic

Set the directional control, so Turn off the engine and

Set the parking
that it is in neutral. remove the key.
brake.
If you must park on uneven ground, be sure to block the
wheels to prevent the lift truck from moving.
Module 4: Lift Truck (Forklift) Safety

Watch where you place your hands and feet. Be aware of

and stay clear of pinch points.
 Staying in your truck includes your hands and
feet.

Stay under the overhead guard. It is designed

to protect you while you operate the truck.
If your truck starts to tip over, DON'T JUMP!

1. Stay in your seat, and go with the truck.

2. Grip the wheel securely.

3. Brace yourself with your feet.

Operating your lift truck safely means you are not only
responsible for your safety, but also for the safety of
the people around you.
Always look out for others before moving your lift
truck.

As you drive, watch out for people walking,

and at intersections, slow down, look for
traffic, and sound your horn frequently.
Remember; ALWAYS come to a complete
stop before changing direction.
 Never let anyone, including yourself, walk or stand
under the forks when they are raised.

Keep in mind that you are a lift truck operator, not a

taxi service. You should never allow anyone to ride
on your lift truck.
You also do not operate an elevator service. Never attempt to lift anyone on your
forks, without using a special basket designed for lifting people safely.

Remember, it's your lift truck. Never let unauthorized personnel use it, and always
remove the key when you have to leave your lift truck unattended.
Seat Belt - Most lift trucks are equipped with a
seat belt. Use it!

Horn - Sound your horn:

* Before backing up
* At intersections
* When traveling through doors
* Anywhere your vision is limited or blocked

Backup Alarm - Some trucks are equipped with a

backup alarm that warns others that you are
backing up. Don't forget to turn around, look, and
sound your horn whenever you backup.
Warning Light - Some trucks are equipped with a yellow
warning light that warns others that you are approaching,
even at a distance.
The most important safety device that is on your lift truck is YOU!

• Stay alert; watch out for others, as well as yourself.

• Monitor the condition of your truck and the area you are working in.
• Wear safety equipment when needed.
• Watch for NO SMOKING areas and hazardous materials which can cause explosions.
• Never use drugs or alcohol before coming to work or on the job.
• Be careful of over-the-counter or prescription drugs that may impair your ability to operate
your lift truck safely.
• Remember that SAFETY is the most important part of your job when operating a lift truck.
• Never use a cell phone while driving.
• Never drive with earphones while operating a forklift.
• Never drive with wet or greasy hands.
• Never engage in horseplay while operating a truck. Practical jokes have been known to kill
people.
• Operation of any of the control levers on your truck from a position other than the driver’s
seat is prohibited.
• If a CO - worker is injured, assist him to First - Aid and report the incident to your
supervisor.
• Always make sure that pedestrian helpers are in the clear.
• Never allow any person to stand or pass under the elevated portion of any fork - lift truck,
loaded or empty.
• Always Report and Incident.
Vehicle Misuse or Abuse:
• Your lift truck must never be used as a jack to lift heavy machines or other
heavy objects, without special permission of your supervisor.
• Never use your truck, or its forks, as battering rams.
• Lift - trucks must not be used for opening or closing the doors of railroad
freight cars or trailer trucks.
• Never tow or push a railroad car with a fork - lift truck.
• Never use your truck with another in a combined lift, unless specifically
authorized to do so by your supervisor.
• Never push another vehicle in order to get it started.

Starts and Stops:

• Never start to move your vehicle, in either direction, until you have
checked to see that your path is clear.
• Avoid sudden starts. A vehicle going in sudden motion might strike a fixed
object or and unsuspecting bystander.
• Avoid sudden stops. A quick stop is and easy way to lose all or part of a
load.
• Never step out of your truck until it has come to a complete stop.
• When a fork - lift truck is not in use, the forks must be fully lowered with
the tips of the forks touching the floor. The controls must be placed in
neutral, and the parking brake must be applied to prevent movement.
Unsafe conditions are identified as the following:
1. Vehicle conditions
2. Floor conditions
3. Floor construction
4. Housekeeping in the travel ways
5. Equipment guarding
6. Ramps
7. Dock conditions
8. Blind corners
9. Congested areas
10. Types of loads transported

Unsafe Acts are identified as the following:

1. Operating to fast
2. Overloading the equipment
3. Stacking unsafely
4. Failure to follow accepted procedures
5. Operating known defective equipment
6. Unawareness of hazards
7. Failure to check dock plates
Accidents and Incidents:
1. Call for help and apply first aid if needed.

2. Report to a supervisor.

3. Make the area safe for you and bystanders.

4. If the injured person can be moved, take

them to hospital or wait for ambulance.

Fire Prevention:
2. If you can and it is safe to do so, put out
the fire yourself.

2 .Call for help and notify your colleagues of

the fire.

3. Report the fire to your supervisor.

4. If it is safe to do so isolate the area by

closing doors and windows.
 Module 5: Maintenance

Begin your daily inspection by filling in your daily checklist (Appendix

B in your manual). The safety equipment you must inspect daily is
your:
* Seat Belt
* Warning Light
* Backup Alarm
* Horn

Steering - Feel the steering action for a

minimum of free play.

The free play in steering should not be more

than one or two inches in either direction that
you turn the wheel.
Brakes - Test your brakes. They should depress smoothly and
should not require excessive force to operate. When pressing the
brakes, the pedal should not sink under continued pressure.
When you drive your lift truck, the brakes should not grab or
cause the truck to swerve. Brakes that make a grinding or
screeching noise need immediate attention.
Also, don't forget to check your parking brake.

Upright - Look for any broken, chipped, misaligned,

warped or worn parts in the chains, hydraulic
cylinder, mast/upright or forks. Remember; DO NOT
PUT YOUR HANDS IN THE LIFT MECHANISM.
Hydraulic Hoses - Visually examine the hydraulic hoses and
connections. Look to make sure the hoses are in good
condition. Check for leaks around fittings and connecting
points.

Hydraulic Controls - The control levers should move smoothly

and return to neutral when released. Feel for roughness in the
action when the forks are raised or tilted. No slipping or moving
of the forks or mast should occur when they are moved to a new
position.
Tires and Wheels - Visually inspect the tires. Look for damage, wear,
missing bolts, or other signs that a tire is not in good condition.
From time to time, check the air pressure in pneumatic tires. Always
use a long tire gauge and face the tread, not the side of the tire, when
checking tire pressure.

Hour Meter - During your inspection, note the engine hour meter. It is
important for scheduling maintenance to keep your truck in good
working order

Leaks - Look for leaks. Brake fluid, transmission oil, radiator coolant,
battery acid (electrolyte), or fuel can leak from your lift truck. DO
NOT DRIVE a lift truck that has a leak. Call maintenance immediately.
Daily Inspection for Combustion Engine Lift Trucks (Gasoline, LP & Diesel
Powered)

Fuel Level

Oil level and Pressure

Water Level

Fan Belt

If you drive a lift truck which uses gasoline, LP, or diesel fuels, be sure to
check the fuel level, oil level and pressure, water level, and fan belt.
 Daily Inspection for Battery Powered Lift Trucks

Battery plug connection

Battery charge

Battery load test

If you drive a battery powered lift truck, check the battery plug connection,
battery charge, and load test the battery.
Daily Operator's Report

It is your responsibility as a lift truck

operator to inspect your lift truck
daily.

Part of the inspection process is to

complete a Daily Operator's Report
by filling in your daily checklist.

This report is used by your

organization to schedule
maintenance, document any
problems, and is required by many
insurance companies.

Remember, it's part of your job to fill

out this report.
Module 6: Re-Fuelling and Re-charging

The greatest danger involved with refuelling or recharging

your lift truck is with fire. As a lift truck operator, you have a
responsibility to refuel or recharge your lift truck safely. To
safely refuel or recharge your lift truck, follow the steps
listed below:

• Park your lift truck in a designated refuelling /

recharging area.

• Do not block doorways or access to production or

emergency equipment.

• Make sure that the area you are using is well ventilated.

• Check to see that there is a fire extinguisher nearby.

Whenever you refuel a gasoline or diesel lift
truck:

1. Turn off the engine and any lights that may

be burning on the lift truck.

2. Do not smoke; make sure there are no open

flames near your lift truck.

3. Be sure there is contact between the spout

and the fill pipe before pumping.

4. Try not to spill any fuel. If you do, clean it

up.

5. If you must use a can to refuel, make sure it

is an approved container for fuels.
Whenever you refuel an LP lift truck:

1. Before replacing an LP gas tank, close the

shut off valve and let the engine run until
it stalls.
2. Turn off the engine and any lights that
may be burning on the lift truck.
3. Check for damage to connections and
look for leaks.
4. WARNING: Since LP gas is heavier than
air, make sure there is plenty of
ventilation before changing or refilling LP
tanks.
5. Do not smoke; make sure there are no
open flames near the lift truck.
Whenever you recharge an electric lift truck:

1. Turn off the motor and any lights that may be burning on
the lift truck.
2. Do not smoke; make sure there are no open flames
nearby.
3. During the recharging process, batteries give off
hydrogen gas. Make sure you recharge your battery in a
well ventilated area.
4. Be careful not to spill any battery acid (electrolyte). If
you do, clean it up using an absorbent material.
5. Because of the danger of electrical arcing, which will
ignite hydrogen gas, keep tools and other metal objects
away from the top of uncovered batteries. This includes
rings and watches.
6. Batteries, when they are recharging, produce heat. Be
sure to keep the compartment lid open.
7. Wear all prescribed safety equipment (face shield,
rubber gloves, rubber apron, etc.).
If you are responsible for changing the battery on your lift truck,
you should:

1. Wear an apron, gloves, and face shield or goggles.

2. Use a non-metallic boom or lift device to prevent sparking.

3. Make sure there is an eye-wash station nearby.

4. Securely strap the battery into place before operating the lift
truck.
 The End
Any Questions ?