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- Herausgeber: After Midnight Publishing
- Kategorie: Lebensstil
- Sprache: Englisch
Material handling equipment refers to a diverse array of machinery, tools, and systems used in the movement, storage, control, and protection of materials, goods, and products throughout the manufacturing, distribution, warehousing, and logistics processes. This equipment is designed to facilitate the efficient, safe, and organized handling of materials, reducing manual labour, minimizing product damage, and optimizing productivity. This book examines the diverse world of material handling equipment, offering in-depth coverage of forklifts, order pickers, telehandlers, elevating work platforms, reach stackers, truck trailer side loaders, and pushback tugger trucks. With a focus on practicality and safety, each section delves into the uses, key components, operating principles, preparation for operations, operational practices, safe operation, and finalizing operations of these essential machines. Additionally, the book introduces vital skills and knowledge required for operating an aircraft push-out tug, including conducting pre-operational checks, operating the tug, and conducting post-operational checks. It also covers the safe operation of forklift trucks, order picking forklift trucks, telehandlers, boom-type elevating work platforms, side loaders, and pushback tractors, emphasizing planning, preparation, execution, and cleanup phases of the work or task. Whether you're a novice or an experienced operator, this book provides invaluable insights and guidance for operating these critical pieces of equipment safely and efficiently.
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Veröffentlichungsjahr: 2024
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Material Handling Equipment Operation
Richard Skiba
Copyright © 2024 by Richard Skiba
All rights reserved.
No portion of this book may be reproduced in any form without written permission from the publisher or author, except as permitted by copyright law.
This publication is designed to provide accurate and authoritative information in regard to the subject matter covered. While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional when appropriate. Neither the publisher nor the author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, personal, or other damages.
Skiba, Richard (author)
Material Handling Equipment Operations
ISBN 978-1-76350-130-0 (paperback) 978-1-76350-131-7 (eBook) 978-1-76350-132-4 (Hardcover)
Non-fiction
Contents
Preface
This book covers a selective range of material handling equipment, specifically forklifts, order pickers, telehandlers. elevating work platforms, reach stackers, truck trailer side loaders and pushback tugger trucks. For each of these, the uses, key components, operating principles, preparation for operations, operational practices, safe operation and finalising operations is covered.
The material handling equipment information provided within this book is intended to be general in nature and may not encompass all aspects of its operation. It is important to note that each item of plant or equipment has its own specific characteristics and operational requirements that may vary. Material handling equipment operators are strongly advised to consult the manufacturer's guides and manuals prior to the operation of any crane to ensure compliance with safety standards and operational procedures.
Furthermore, it is crucial to acknowledge that operations and terminology can differ across jurisdictions. Material handling equipment operators should be aware that regulations and guidelines pertaining to equipment usage may vary depending on the location. Therefore, it is essential for crane operators to familiarize themselves with the applicable laws, regulations, and standards in their respective jurisdictions.
Additionally, material handling equipment operators are urged to review workplace policies and procedures before operating any crane. Workplace-specific protocols may exist to address unique hazards and safety considerations, which must be adhered to for safe crane operation.
Moreover, it is important to recognize that in many jurisdictions, operational licensing requirements apply. Material handling equipment operators are responsible for ensuring that they meet all jurisdictional legislative requirements relevant to their sites of practice. This may include obtaining appropriate licenses, certifications, or permits to operate cranes legally and safely within their jurisdiction.
Sample load charts, specifications, interpretations and calculations are used throughout this book for demonstration purposes only and should not be taken to be sued in any other manner. Every equipment model is accompanied by its own distinct load chart and characteristics, which may vary depending on the equipment's configurations and rated capacity and is supplied by the equipment’s manufacturer. They are not portable from one model to another, and operators must always ensure they are referring to documentation relevant to the plant they are operating.
While efforts have been made to provide accurate and informative equipment operation information, users are reminded of the need for due diligence and compliance with applicable regulations, manufacturer guidelines, workplace policies, and licensing requirements to ensure safe and lawful crane operations.
Introduction
Material Handling Equipment (MHE) constitutes a versatile array of machinery and tools utilized across manufacturing, distribution, warehousing, and logistics processes to facilitate the movement, storage, protection, and control of materials and products. This equipment forms an integral component of industrial and commercial settings, ensuring the smooth flow of materials within various operations. MHE encompasses a diverse range of machinery and tools, including forklifts, conveyors, cranes, pallet jacks, hoists, elevating work platforms, reach stackers, and order pickers, among others. Each type of equipment serves specific purposes and is tailored to handle distinct materials and loads efficiently.
The primary functions of material handling equipment revolve around lifting, transporting, positioning, sorting, storing, and safeguarding materials and products. As an example, forklifts are commonly employed for lifting and transporting heavy loads, conveyors facilitate the movement of materials along fixed paths, while pallet jacks are utilized for loading and unloading palletised goods. Efficient material handling is pivotal for optimizing productivity, reducing labour costs, minimizing material damage, and ensuring workplace safety.
Proper selection and utilization of material handling equipment streamline operations, improve workflow, and enhance overall efficiency in industrial and warehouse environments. Safety remains a paramount concern in material handling operations, necessitating thorough operator training and adherence to safety protocols to prevent accidents, injuries, and damage to goods. Integration with inventory management software, warehouse management systems (WMS), and enterprise resource planning (ERP) systems enables seamless coordination and control of material flow throughout the supply chain. Material handling equipment plays an indispensable role in modern manufacturing, distribution, and logistics operations, contributing significantly to increased efficiency, productivity, and safety in handling materials and products.
A forklift, also known as a lift truck, fork truck, or forklift truck and as shown in Figure 1, is a powered industrial truck used to lift, move, and stack materials. It typically features two forks at the front that can be raised and lowered for lifting and carrying loads. Forklifts are widely used in warehouses, distribution centres, manufacturing facilities, and construction sites to handle a variety of materials, including palletised goods, crates, boxes, and other heavy items.
Forklifts come in various sizes and configurations, ranging from small electric-powered models for indoor use to larger diesel-powered or propane-powered models for outdoor and heavy-duty applications. They are equipped with different types of tyres suitable for different surfaces, such as solid rubber tyres for indoor use and pneumatic tyres for outdoor use.
Operators control forklifts using a steering wheel and pedals to manoeuvre the vehicle and lift and lower loads. They are trained to operate forklifts safely, adhering to specific procedures and safety protocols to prevent accidents, injuries, and damage to goods. Forklifts are essential equipment in material handling operations, offering efficiency and versatility in lifting and transporting materials within industrial and commercial environments.
An order picker, also known as a stock picker or order selector, is a type of forklift designed specifically for use in warehouses and distribution centres to fulfill orders and retrieve items from storage shelves or racks. Unlike traditional forklifts that lift and carry loads on pallets, order pickers feature a platform or cage that lifts the operator vertically to reach items stored at various heights.
Order pickers are typically used in facilities with high-density storage systems, where items are stored on multiple levels of shelving or racking. The operator stands on the platform, which can be raised and lowered hydraulically, allowing them to access items on different shelves without the need for a separate ladder or elevated platform.
Operators use order pickers to navigate through aisles and select specific items from storage locations based on customer orders or inventory requirements. This process is known as order picking or order selection. Order pickers are equipped with controls for steering, lifting, and lowering the platform, as well as safety features such as guardrails and harnesses to protect the operator while working at heights.
Order pickers play a crucial role in warehouse operations, helping to increase efficiency and accuracy in order fulfillment processes. They enable operators to quickly and safely access items stored at various heights, allowing for more efficient picking and packing of orders and improving overall productivity in the warehouse.
A telehandler, see Figure 3, also known as a telescopic handler or a telescopic forklift, is a versatile piece of material handling equipment commonly used in construction, agriculture, and industrial settings. It features a telescopic boom or arm that can extend forward and upward, with attachments such as forks, buckets, or platforms at the end.
Telehandlers are designed to lift, move, and place heavy loads or materials in areas that are difficult to reach with conventional forklifts or cranes. They offer greater reach and flexibility compared to traditional forklifts, making them suitable for a wide range of applications.
These machines are equipped with hydraulic systems that control the extension and retraction of the boom, as well as the lifting and lowering of the attached load. Some telehandlers also have features like 360-degree rotation of the boom and outriggers for added stability when lifting heavy loads at height.
In construction, telehandlers are often used for tasks such as lifting and positioning building materials like pallets of bricks or bags of cement, transporting materials across uneven terrain, and working at height to place loads on rooftops or upper floors of buildings. In agriculture, they are utilized for tasks such as loading and stacking hay bales, moving feed or equipment, and operating various attachments for handling crops.
Overall, telehandlers are valued for their versatility, manoeuvrability, and ability to perform a wide range of tasks in diverse environments, making them essential equipment in many industries.
An elevating work platform (EWP), also known as an aerial work platform (AWP) or a mobile elevated work platform (MEWP), is a mechanical device used to provide temporary access to elevated areas for work purposes. EWPs are commonly used in construction, maintenance, repair, installation, and cleaning tasks where workers need to reach heights that are beyond the reach of ladders or scaffolding.
These platforms typically consist of a work platform or basket that is mounted on a mechanical arm or boom, which can be raised, lowered, and maneuvered to the desired height. The platform may be supported by hydraulic, pneumatic, or mechanical systems, allowing it to be elevated vertically or extended horizontally.
There are various types of elevating work platforms, including:
Scissor Lifts: These platforms have a scissor-like mechanism that extends vertically, providing a stable and relatively large work area. Scissor lifts are commonly used for indoor maintenance and construction tasks.
Boom Lifts: Also known as cherry pickers or telescopic booms, these platforms feature an extendable boom that can reach up and over obstacles, allowing workers to access elevated areas at varying heights and distances. See Figure 4 for an example.
Vertical Mast Lifts: These platforms have a single vertical mast that raises the work platform vertically. They are suitable for tasks that require access to tight or confined spaces, such as warehouses or narrow aisles.
Personnel Lifts: These compact lifts are designed for vertical access to elevated areas and are often used for tasks like changing light fixtures, painting, or ceiling repairs.
Elevating work platforms are equipped with safety features such as guardrails, harness attachment points, emergency lowering systems, and stability controls to ensure the safety of operators and workers. Proper training and certification are typically required for individuals operating EWPs to prevent accidents and ensure safe use.
A reach stacker, as shown in Figure 5, is a specialized type of material handling equipment used in ports, shipping terminals, and container yards for lifting, moving, and stacking ISO standard shipping containers. These heavy-duty vehicles are designed to handle containers of various sizes and weights with efficiency and precision.
The main components of a reach stacker include a lifting frame, telescopic boom, spreader attachment, and a chassis with wheels for mobility. The telescopic boom can extend and retract, allowing the reach stacker to lift containers from ground level or from atop other containers, reaching heights sufficient for stacking or loading onto trucks, railcars, or ships.
Reach stackers are highly versatile and can handle containers in various configurations, including single, double, or triple stacks. They are equipped with sophisticated hydraulic systems for precise control of lifting, lowering, and positioning of containers. Some reach stackers also feature rotating cabs, allowing operators to have a better view of the work area and improve manoeuvrability.
These vehicles play a crucial role in container logistics, facilitating the efficient movement of containers between different modes of transportation and storage facilities. They help optimize container handling operations, reduce turnaround times, and improve productivity in ports and terminals.
Safety is a paramount consideration when operating reach stackers due to the heavy loads and potential risks involved. Operators must undergo specialized training and certification to ensure safe and proficient operation of these machines. Additionally, reach stackers are equipped with safety features such as overload protection, stability control systems, and alarms to prevent accidents and ensure the well-being of workers and equipment.
A truck trailer side loader, also known as a sidelift or sidelifter, is a specialized type of trailer used for transporting and loading ISO shipping containers. Unlike traditional trailers that require external lifting equipment like cranes or forklifts to load and unload containers, a side loader has built-in hydraulic lifting mechanisms that allow it to lift containers on and off the trailer without additional equipment.
The truck trailer side loader consists of several key components essential for its operation. Firstly, the chassis provides the structural framework of the trailer, constructed from steel to withstand the weight of loaded containers. Secondly, the hydraulic lifting mechanism, powered by hydraulic cylinders, pumps, and controls, facilitates vertical movement of containers onto or off the trailer. Telescopic arms extend horizontally from the trailer's sides to engage with containers, their hydraulic adjustments accommodating various container sizes. Twist locks secure containers to the arms during transportation. A control panel, situated near the operator's cab, houses controls for hydraulic functions and twist lock engagement. Finally, the operator's cab contains steering controls, hydraulic levers, and monitoring gauges, allowing for safe and efficient operation of the side loader.
Truck trailer side loaders are commonly used in intermodal freight transportation and logistics operations, where they offer significant advantages in terms of speed, flexibility, and efficiency compared to traditional loading methods. They are particularly useful in areas where access to cranes or forklifts is limited or where rapid container handling is required.
A pushback tugger truck, commonly known as a pushback tractor, is a specialized vehicle used at airports for manoeuvring aircraft on the ground. It is primarily employed for pushing back aircraft from the terminal gate to the taxiway, as well as for repositioning aircraft within the apron area.
A pushback tugger truck, essential for manoeuvring aircraft on the ground at airports, comprises several key components. These include the chassis, providing structural support for the vehicle and designed to endure the stresses of pushing heavy aircraft. Powered by a robust engine, typically diesel, it delivers the necessary torque for moving large commercial planes. The transmission system facilitates smooth acceleration and deceleration, with options ranging from automatic to manual transmissions. A towing hitch at the front enables connection to aircraft for towing via towbars or towbarless systems. The operator's cab houses steering controls, pedals, and monitoring instruments for vehicle performance, while some models feature hydraulic systems aiding in steering, braking, and providing additional power for heavy pushes. Additionally, towing equipment varies based on aircraft type, accommodating different towing methods such as towbars or towbarless systems.
Forklifts
Forklift trucks are essential for transporting and stacking materials efficiently within various industrial and warehouse settings. They typically feature a short wheelbase and a vertical mast, facilitating the vertical movement of loads. Forklift trucks come in two main types: counterbalanced and non-counterbalanced.
Counterbalanced forklift trucks, see Figure 9, utilize the front wheel axle as a fulcrum, akin to a lever. The load is counterbalanced on one side by the weight of the machine on the other side. This design allows all the weight behind the point of balance to act as a counterweight, ensuring stability during lifting and stacking operations.
On the other hand, non-counterbalanced forklift trucks see Figure 10, such as 'reach' or 'straddle' trucks, have the centre of the load positioned behind the fulcrum point. These trucks are adept at reaching out to deposit loads or straddling stacks for load deposition. It's crucial to note that they should not carry loads unless the reach is retracted. Non-counterbalanced forklifts are particularly useful for specific load stacking tasks and offer greater versatility than their counterbalanced counterparts, especially in warehouse environments where manoeuvrability and precise load placement are paramount.
Forklifts are designed with a 3-point suspension system, even in four-wheel counterweighted forklifts, where the rear wheels are centrally attached to the main body, allowing for lateral movement that affects stability (Sanders, 2008). The combination of a high centre of gravity and a narrow wheelbase further contributes to their lateral instability (Sanders, 2008).
Forklifts have 3-point suspension formed from the front drive axle (a and b) and the steering axle point at the rear of the base (c). As such, the centre of gravity (CoG) changes between a loaded and unloaded forklift as shown in Figure 11 and Figure 12.
Center of gravity (CG) is the point at which the entire weight of an object can be considered to act, causing the object to behave as if all its mass were concentrated at that single point. In simpler terms, it's the point around which an object's mass is evenly distributed in all directions.
In the context of forklifts, understanding the centre of gravity is crucial for safe operation. Forklifts are designed to lift and carry heavy loads, and the distribution of weight plays a significant role in their stability and manoeuvrability. Here's how the centre of gravity relates to forklifts:
Stability: The stability of a forklift depends on the position of its centre of gravity relative to its wheelbase. Ideally, the centre of gravity should remain within the triangle formed by the forklift's three points of contact with the ground: the two front wheels and the rear steering axle. If the centre of gravity shifts outside this triangle, especially towards the rear or sides, the forklift becomes unstable and prone to tipping over.
Load Handling: When lifting a load with a forklift, the centre of gravity of the combined forklift and load system changes. Forklift operators must ensure that the load is properly balanced and centred on the forks to maintain stability. If the load is unevenly distributed or too heavy, it can cause the centre of gravity to shift, increasing the risk of tipping.
Cornering and Manoeuvring: During turns and manoeuvres, forklift operators must be mindful of the shifting centre of gravity. Sharp turns or sudden changes in direction can cause the forklift's centre of gravity to shift, potentially leading to instability. Operators should avoid abrupt movements and maintain a slow, controlled speed to minimize the risk of tipping.
Overhead Clearance: Forklifts often operate in areas with limited overhead clearance, such as warehouses and loading docks. Operators must be aware of the forklift's mast height and the location of the load relative to the centre of gravity to avoid collisions with overhead obstacles. Raising the mast too high or carrying a load that extends beyond the forklift's stability limits can compromise safety.
Forklift Components
Forklifts consist of numerous components and mechanisms essential for their proper functioning. Familiarizing oneself with the terminology and structure of these parts is crucial for clear communication with colleagues during work tasks. Below are some key elements and components that constitute the anatomy of a forklift truck. The key components are shown in Figure 13.
The mast of a forklift serves as the vertical support structure responsible for raising and lowering loads. Positioned typically towards the front of the forklift, the mast lies within the operator's line of vision, allowing for efficient operation. Forklift masts are equipped with various sections, such as duplex, triplex, or quad configurations, enabling the elevation or descent of the forklift carriage along with the forks. Understanding the features and terminology associated with forklift masts, including lift height, free lift height, extended height, and lowered height, is essential when selecting a forklift tailored to specific operational requirements (Logisnext, 2024).
The lift cylinder of a forklift is responsible for powering the vertical movement of the mast, enabling the raising or lowering of the forklift carriage and forks. Operating hydraulically, the lift cylinder functions as a single-acting hydraulic cylinder, exerting force in one direction. Similarly, the tilt cylinder controls the tilt movement of the carriage and adjusts the angle of the forks relative to the ground. The forklift carriage assembly, positioned in front of the mast, serves as a platform for mounting objects controlled by the mast, including the forks and load backrest. Forks, also known as tynes, are the components directly engaging with loads for transport, available in various sizes and shapes to accommodate diverse applications (Logisnext, 2024).
Additionally, the load backrest, attached to the carriage, provides a surface to support loads and prevents them from slipping backward during lifting and travel. It also safeguards the mast components from damage. The counterweight, installed onto the forklift, helps offset the weight being lifted, ensuring stability during lifting and traveling operations. Serving as the power source, forklifts can be powered by engines or batteries, depending on the type. Tire types, including cushion and pneumatic tyres, vary based on operational requirements, with different tire layouts catering to indoor or outdoor environments. The operator cab, whether open or enclosed, houses the controls and features necessary for forklift operation, while the overhead guard enhances safety by protecting operators from falling objects (Logisnext, 2024). Understanding the anatomy of a forklift is crucial for safe and efficient operation in various industrial settings.
Forklift designs vary, and not every forklift configuration will include all the features discussed above.
Forklifts offer a range of customizable options, including fuel type, capacity, lift height, and mast options, among others. When considering purchasing a forklift, it's crucial to consult experienced professionals who can guide you in making the best decision based on your business's materials handling requirements.
The following outlines the various fuel types available for forklifts, delineating their purposes and advantages across different applications. Understanding these fundamentals will aid in selecting the optimal forklift for your business's materials handling needs.
Electric Forklifts: Battery Electric Forklift
Electric-powered forklifts are predominantly utilized for indoor materials handling, especially on flat, concrete surfaces. One significant advantage of battery electric forklifts is their eco-friendliness, as they do not produce harmful emissions from burning fossil fuels. They are cost-effective to operate and operate quietly, reducing noise pollution in the workplace. Recent advancements in technology have substantially improved the performance of forklift batteries, allowing for longer operating hours, typically covering an 8-9 hour shift. Although the initial cost of electric materials handling equipment may appear higher, the long-term savings on maintenance and charging make it the most cost-effective fuel option.
LPG and Petrol Forklifts: Dual Fuel Engine Forklift
LPG and Petrol-powered forklifts, also known as internal combustion forklifts, are better suited to heavier handling tasks and outdoor environments. Modern models feature fuel-efficient technology and lower emission rates compared to older versions. These forklifts can operate for extended periods and can be conveniently refuelled when necessary, unlike electric forklifts that require charging cycles between uses. LPG and Petrol-powered forklifts often come with dual fuel capabilities, allowing owners to switch between fuel types as needed. LPG is particularly popular due to its easy availability and quick replacement process. However, if onsite refuelling stations are unavailable, LPG may be the preferred fuel option. When opting for a forklift with dual fuel capabilities, it's essential to inspect and service both fuel delivery systems regularly to maintain engine performance.
Diesel Forklifts: Powerful Diesel Engine Forklift
Diesel engines offer greater power output, making them ideal for larger forklifts and outdoor, rough terrain, and heavy handling applications. Although diesel forklifts incur higher fuel and maintenance costs in the long run, they are well-suited for industrial applications with rigorous handling requirements.
LPG, Petrol and Diesel Forklifts: Forklifts powered by fossil fuels can be employed for indoor and container handling applications, provided that the indoor areas are well-ventilated. Operators and onsite personnel should be equipped with appropriate personal protective equipment to mitigate risks associated with inhaling hazardous emissions and industrial noise. Regular servicing and daily inspections of fluid levels are crucial for minimizing ongoing maintenance costs and ensuring optimal forklift performance over its lifespan. Adhering to manufacturers' specifications for servicing prevents damage to major components and enhances overall forklift performance.
Working Load
The working load of a forklift refers to the maximum weight that the forklift can safely lift and transport under normal operating conditions. Understanding and adhering to the working load limits of a forklift is crucial for ensuring safety in the workplace and preventing accidents, injuries, and damage to property.
Each forklift model is designed with a specific working load capacity, which is determined by factors such as the design of the forklift, the structural strength of its components, and the stability of its operation. Exceeding the working load capacity of a forklift can lead to instability, tipping, or structural failure, posing serious risks to operators and bystanders.
To determine the working load capacity of a forklift, operators should refer to the manufacturer's specifications, which are typically displayed on a rating plate or capacity plate affixed to the forklift. This information includes the maximum load capacity at various load centres, lift heights, and fork configurations. It is essential to consult this information before operating the forklift and to ensure that loads do not exceed these specified limits.
Factors that can affect the working load capacity of a forklift include the position of the load on the forks, the height to which the load is lifted, and the stability of the ground surface. Operators should also consider environmental conditions such as wind, slope, and obstacles that may impact the safe operation of the forklift.
In addition to knowing the working load capacity of the forklift, operators should also be trained in proper load handling techniques, including how to safely position, secure, and transport loads. Regular maintenance and inspections of the forklift, including its lifting mechanisms and structural components, are essential for ensuring continued safe operation and preventing overloading issues.
By understanding and adhering to the working load limits of a forklift, operators can help maintain a safe working environment and prevent accidents and injuries associated with overloaded or improperly handled loads.
A forklift's load capacity refers to the maximum weight it can safely carry at a specified load centre. If the load is not positioned precisely at the designated centre, the forklift's capacity will be reduced accordingly.
The load capacity data plate provides information about the load each forklift can safely handle under various conditions, including different mast angles or when equipped with attachments. This plate typically includes details such as the load capacity, lift height, load centre distance, brand, and model number. Additionally, it may indicate:
Any reduction in lifting capacity when a mast is attached.
Specific down ratings for identified attachments listed on the capacity plate.
As an example of a load plate, Figure 17 shows the load plate for a Clark CY100PD, shown as Figure 18.
The Load capacity data plate shown in Figure 17 indicates that the forklift has a load centre of 600mm and maximum lift height of 3403 mm. The load centre refers to the horizontal distance from the face of the forks to the centre of gravity of the load being carried. It is a crucial factor in determining the stability and safe handling of loads by a forklift.
The load centre is typically measured from the front face of the forks to the centre of the load being lifted. For standard loads, this distance is often standardized, such as 24 inches (600 mm) or 48 inches (1200 mm). However, it can vary depending on the dimensions and weight distribution of the load. Figure 20 shows another example data plate, also with a load centre of 600mm.
Understanding the load centre is essential because it directly affects the forklift's stability and lifting capacity. When a load is positioned farther from the forklift's mast, it creates a greater moment or leverage, which can make the forklift less stable and reduce its lifting capacity. Conversely, positioning the load closer to the mast decreases the leverage and enhances stability.
When attachments are added to a forklift, it can alter the dynamic and operational characteristics of the vehicle. It's crucial for attachments to have both rated and de-rated capacities. Operators should have access to information regarding the de-rated capacity of the forklift when attachments are utilized.
The load-carrying capacity of a forklift is significantly influenced by the lift height or maximum fork height. Forklifts with taller masts may have a higher carrying capacity at lower lift heights compared to maximum lift heights. Therefore, some forklifts with tall masts may feature a dual capacity rating, allowing operators to handle heavier loads at lower heights.
Insufficient understanding of a forklift's load capacity poses serious risks to operators and those around them. Forklift operators should be knowledgeable about:
How a load's weight, shape, and size affect the forklift.
The correct method for positioning a load.
The distinction between the forklift's model number and its load capacity plate.
Stability
Lateral instability, in the context of forklifts, refers to the tendency of a forklift to tip over sideways due to an imbalance in the distribution of weight. Forklifts are designed with a narrow wheelbase relative to their height, which can make them susceptible to tipping if they are not operated with care, especially when carrying heavy loads or navigating uneven terrain.
Several factors can contribute to lateral instability in forklifts:
Uneven Weight Distribution: If the load being carried by the forklift is not properly centred or is disproportionately heavy on one side, it can cause the forklift to lean to one side, increasing the risk of tipping over.
High Center of Gravity: Forklifts typically have a high centre of gravity due to their elevated masts and loads being carried at height. This high centre of gravity makes them more prone to tipping over sideways, especially when turning or negotiating slopes.
Cornering at High Speeds: Making sharp turns or cornering at high speeds can destabilize a forklift, particularly if the operator does not reduce speed or counterbalance the centrifugal force generated during the turn. This can lead to lateral instability and potential tipping.
Uneven or Sloped Terrain: Operating a forklift on uneven or sloped terrain can exacerbate lateral instability. The incline of the terrain can shift the centre of gravity of the forklift and its load, increasing the risk of tipping over sideways.
Sudden Stops or Acceleration: Abrupt stops or rapid acceleration can disrupt the balance of a forklift, especially if it is carrying a heavy load. The inertia generated by sudden changes in motion can cause the forklift to lean to one side, leading to lateral instability.
To mitigate the risk of lateral instability and tipping, forklift operators should undergo proper training on safe operating procedures. They should also ensure that loads are properly secured and evenly distributed on the forks, avoid excessive speeds and sharp turns, and be cautious when operating on uneven terrain. Regular maintenance of forklifts, including checking tire pressure and ensuring proper functioning of stability systems, can also help prevent lateral instability accidents.
Take note of the following factors that can influence lateral instability:
Making sharp turns at high speeds
Driving across uneven terrain
Load distribution that is not balanced
Operating with a flat or under-inflated tire
Excessive speed while driving
Traveling with the load raised
Applying excessive braking force during turns
Misalignment of the side shift function
Lifting a load with only one fork arm
Moving sideways on a sloped surface
Pulling a load sideways using a jib attachment.
In a forklift, the front wheels serve as a pivot point, with the forks on one side and the machine body on the other. If the weight on the fork ends outweighs the counterweight, it can lead to longitudinal instability, causing the forks to tip upward.
Longitudinal instability, in the context of a forklift, refers to the tendency of the forklift to tip forward or backward due to an imbalance in the distribution of weight along its length. This imbalance can occur when the weight of the load being lifted by the forks exceeds the counterweight of the forklift, causing the front or rear end of the forklift to lift off the ground.
When longitudinal instability occurs, it poses a significant safety risk as it can lead to the forklift tipping over, potentially causing injury to the operator and damage to property. Factors that can contribute to longitudinal instability include carrying heavy loads, improper load distribution, and operating on uneven terrain.
To mitigate the risk of longitudinal instability, forklift operators must adhere to safe operating practices, such as ensuring proper load distribution, avoiding excessive speeds, and not lifting loads beyond the rated capacity of the forklift. Additionally, regular maintenance and inspections of the forklift's components, such as its tyres, brakes, and hydraulic systems, are essential to prevent instability-related accidents.
Operators need to be mindful of the following factors that can contribute to longitudinal instability:
Exceeding the forklift's load capacity
Applying abrupt or severe braking
Improperly adjusting the mast tilt, particularly when carrying loads at elevated heights
Failing to position the load securely against the heel of the fork arms
Shifting the load's centre of gravity forward
Pulling a load towards the forklift's front using a jib attachment
Lifting a load with a tilted-forward mast when using a jib
Handling oversized loads
Installing slipper forks
Operating the forklift with the reach extended.
Planning for Work
To ensure proper task execution and safety protocols, several steps should be followed:
Firstly, task requirements must be extracted from work orders or equivalent documents and verified with relevant personnel involved. This involves a thorough review of the provided instructions and consultation with supervisors or colleagues to ensure alignment and clarity regarding the scope of work.
Next, adherence to workplace procedures for site inspections is crucial. Familiarization with these protocols is essential, followed by a comprehensive assessment of the work area to identify any potential hazards or limitations that could impact forklift operations. Detailed documentation of findings, including identified hazards, is imperative for further action.
Subsequently, evaluating the suitability of the operating surface for forklift truck usage is paramount. This involves assessing surface conditions such as terrain and gradients to determine compliance with safety requirements. Any issues detected must be promptly addressed to mitigate risks to forklift operation.
Moreover, determining the compatibility of the forklift truck and its attachments with the intended load requirements is essential. This entails referencing manufacturer specifications to ascertain working load limits and evaluating the weight and dimensions of the load(s) to be handled. Compliance with specified limits ensures safe handling of loads.
Additionally, identifying and managing appropriate paths for forklift operation within the work area is vital. This involves mapping out safe pathways, managing traffic flow, and effectively communicating designated routes to forklift operators and other personnel.
Furthermore, identifying and reporting hazard and risk control measures to relevant personnel is critical. This requires a proactive approach to identifying potential hazards associated with forklift operations, assessing associated risks, and promptly reporting findings to supervisors for mitigation.
Ensuring the implementation of a traffic management plan in accordance with workplace procedures is also essential. This involves reviewing and confirming adherence to established traffic management protocols, including designated routes, signage, and communication protocols.
Moreover, identifying appropriate communication procedures with relevant individuals is imperative for ensuring effective coordination and safety. This involves determining communication needs, selecting suitable methods, and clearly communicating procedures to all involved parties.
Finally, confirming coverage of work/task requirements for the relevant work area is essential for task completion and compliance. This entails reviewing identified requirements, confirming task completion, and documenting any deviations or outstanding tasks for record-keeping and future reference.
Every workplace poses potential risks that could lead to dangerous situations. Therefore, operators must conduct thorough inspections of the workplace to identify and mitigate any hazards before commencing forklift operations. In some cases, obtaining a work permit may be necessary to ensure safety compliance.
Key factors to be mindful of include:
Direction of traffic flow
Blind spots and corners
Cross traffic in blind alleyways
Inclines or slopes
Ceiling clearance, including low-hanging pipes
Doorway clearances
Characteristics of the load (flammable, fragile, unstable, hot)
High temperatures, especially in areas where LP gas is used
Condition of road surfaces
Emissions from the forklift
Presence of electric overhead wires
It's crucial for other workers and pedestrians to understand the importance of keeping a safe distance from forklift operations, especially during loading, stacking, or when loads are elevated. Any unsafe practices observed should be promptly reported to management. Safety measures such as signage, barriers, and the use of horns and warning lights should be employed to alert personnel about forklift activities, particularly when operating in public areas.
Employers bear the responsibility of providing safe workplaces for all employees and visitors. All parties involved in the workplace must ensure that forklifts are operated safely. Designing separate zones for pedestrians and forklifts in new workplaces can further enhance safety measures.
Before operating a forklift, a thorough assessment of the workplace and environmental conditions should be conducted to identify and address any potential risks of injury or damage to equipment or loads. While the provided checklist serves as a useful guide, it should be customized to suit individual forklifts and their operating environments. Utilizing the checklist can help ensure safe and efficient forklift operations, minimize injuries, and rectify any unsafe practices.
If you are involved in the storage or handling of flammable dangerous goods, it is essential to adhere to the following guidelines:
Review Material Safety Data Sheets (MSDS) and package labelling to identify the hazardous properties of each flammable dangerous good.
Classify areas within the workplace where flammable liquids, gases, or solids are stored or handled as hazardous areas according to relevant standards, for example AS/NZS 60079.10.1:2009 Explosive atmospheres – Classification of areas – Explosive gas atmospheres (IEC 60079-10-1, Ed.1.0(2008) MOD).
Mark each hazardous area with appropriate markings, warning lights, and signs.
Keep ignition sources separated from hazardous areas by an appropriate distance or physical barriers.
Provide comprehensive training and supervision to workers regarding the risk of ignition sources and methods for preventing fire or explosion.
Avoid using spark ignition forklift trucks (including petrol and LP gas-powered) in any hazardous area.
Refrain from using any forklift trucks in areas where flammable atmospheres exist continually (zone 0 area), ensuring these areas are free from sources contributing to the flammable atmosphere before forklift entry.
Strictly adhere to hot work permits at all times, including measures such as monitoring flammable vapor and gas, inspecting the area and forklift before entry, ensuring adequate ventilation, and shutting down processes or materials that may contribute to a flammable atmosphere.
Utilize forklift trucks compliant with relevant standards, such as AS 2359.12-1996 or non-spark ignition engines in zone 1 areas, implementing an appropriate hot work permit system.
Use modified forklift trucks or non-spark ignition engine forklifts with an effective hot work permit system in zone 2 areas where flammable atmospheres may occur for short periods.
Employ forklift trucks specifically designed for use in explosive or flammable areas, ensuring compliance with relevant Australian Standards.
Provide thorough training to all employees on eliminating risks associated with handling flammable atmospheres and materials, as well as potential ignition sources.
Enforce a strict 'no smoking' policy in refuelling or battery charging areas.
Avoid using naked flames when checking levels of battery cells.
Handle and store liquid fuel and LP gas in accordance with relevant Australian Standards.
Ensure adequate ventilation in workplaces using LP gas, petrol, or diesel-powered forklift trucks.
Refuel, park, and store LP gas-powered forklift trucks in well-ventilated areas away from combustible material and sources of heat or ignition, ensuring the LP gas cylinder is turned off when not in use.
Replace LP gas cylinders following procedures compliant with relevant Australian Standards.
Recharge and change batteries following correct procedures and in accordance with relevant standards, ensuring the park brake is applied and vent caps are functional.
Prevent the build-up of flammable gases during battery charging by keeping the battery cover open.
Use appropriate tools and keep metal objects away from battery cells during battery changing or charging.
Avoid using liquids with a flashpoint below 61 degrees Celsius for cleaning forklift trucks.
Adhere to recommendations from flameproofing companies regarding the inspection and maintenance of flameproofing features for flameproofed forklifts.
Establish and maintain procedures for diesel forklifts with flameproofing, ensuring the spark arrestor tank on the exhaust line is attended to as recommended by the flameproofing company.
Areas where flammable liquids are stored or used are typically designated as having a "hazardous atmosphere". Before being used in such environments, forklifts must undergo modification or "flame proofing" and have a compliance plate indicating this. Diesel-powered forklifts that are flame proofed feature an exhaust water wash box, which needs to be flushed and refilled at the start of every shift. Battery-powered forklifts with flame proofing should not be connected to the battery charger near areas where flammable liquids are handled in open containers. Petrol and LP gas forklifts are not flame proofed due to their spark ignition system.
Extreme caution is necessary when operating forklift trucks in flammable atmospheres or when handling flammable materials. Safe work practices are crucial during refuelling or battery charging. Potential ignition sources include sparks or flames from the exhaust, engine heat, flashback from vapours drawn into the engine, over-revving, excess speeding, sparks from brake components, sparks from tynes striking concrete, static electricity from tyres, or arcs from electrical equipment.
Using non-flameproof forklift trucks in areas where flammable dangerous goods are handled can pose an immediate risk of fire or explosion. Such forklifts should not be allowed into areas where fuels and other flammable materials are mixed, transferred, or decanted.
It's not typical for forklift trucks to be manufactured as flameproof. Flameproofing is usually done as a specialized engineering activity after the initial manufacturing process. The extent of flameproofing depends on the flammable zones where the machine will operate (Zone 1 or Zone 2, never Zone 0). Not all forklift trucks can be economically flameproofed. Generally, it's cost-effective to flameproof forklift trucks with compression engines (diesel fuel) or electric engines but not those with spark ignition engines (LPG fuel or petrol).
