Attachment 9 Tab D Technical Library 20230327.pdf

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DEPARTMENT OF THE AIR FORCE

Headquarters US Air Force

QTP24-3-E814

24 May 2019

Washington, D.C. 20330-1030

Forklift Vehicle Management Codes: E814 – E816, E819, E820, E822 – E826, E828 –

E842, E844 – E847, E849 – E851, E853 – E859, E860, E886, E895, E948, E949, E952, E954, E956 – E959, E977, E979 – E981, F816, F822, F842

QUALIFICATION TRAINING PACKAGE

CONTENTS

SECTION 1—OVERVIEW

1.1. Overview

SECTION 2—RESPONSIBILITIES

2.1. Responsibilities

SECTION 3—INTRODUCTION

3.1. Objectives:

3.2. Desired Learning Outcomes:

3.3. Lesson Duration

3.4. Instructional References

3.5. Instructional Training Aids and Equipment

3.6. Suggested Sources for Obtaining Supplemental Training Material

SECTION 4—TRAINEE PREPARATION

4.1. Licensing Requirements

4.2. Required Reading

SECTION 5—KNOWLEDGE LECTURE

5.1. Knowledge Overview (Lecture)

5.2. Overview of Training and Requirements

5.3. Vehicle Inspection

5.4. Vehicle Safety and Equipment

5.5. Driving Safety and Precautions

5.6. Forklift Load Composition and Stability

5.7. Forklift Loading and Unloading

5.8. Forklift Operation

SECTION 6—EXPLANATION AND DEMONSTRATION

6.1. Instructor’s Preparation

6.2. Safety Procedures and Equipment

6.3. Operator Maintenance Demonstration

6.4. Operation Demonstration

SECTION 7—TRAINEE PERFORMANCE AND EVALUATION

7.1. Trainee Performance

7.2. Performance Evaluation

Attachment 1—GLOSSARY OF REFERENCES AND SUPPORTING INFORMATION 46 Attachment 2—VEHICLE INSPECTION GUIDE 47 Attachment 3—PERFORMANCE TEST 57 Attachment 4—SEVEN-STEP INSPECTION PROCESS 61 Attachment 5—FORKLIFT OPERATION REVIEW QUESTIONS 70

Section 1—OVERVIEW

1.1. Overview.

1.1.1. Send comments and suggested improvements on AF Form 847, Recommendation for Change of Publication through Air Force Installation and Mission Support Center (AFIMSC) functional managers via e-mail at AFIMSC.IZSL.VehicleOps@us.af.mil.

1.1.2. How to use this plan:

1.1.2.1. Trainer:

1.1.2.1.1. Provide overview of training, Section 2 and Section 3.

1.1.2.1.2. Trainer’s lesson plan for trainee preparation, give classroom lecture, Section 4.

1.1.2.1.3. Trainer’s lesson plan for knowledge lecture, Section 5.

1.1.2.1.4. Trainer’s lesson plan for demonstration, Section 6.

1.1.2.1.5. Trainer’s lesson plan for performance and evaluation, Section 7.

1.1.2.2. Trainee:

1.1.2.2.1. Reads entire lesson plan prior to classroom lecture.

1.1.2.2.2. Follows along with lecture using this lesson plan and its attachments.

1.1.2.2.3. Accomplishes forklift operation review questions (Attachment 5) with trainer.

1.1.2.2.4. Uses Attachments 2 and 4 as guides for vehicle inspection.

1.1.2.2.5. Takes performance test.

Section 2—RESPONSIBILITIES

2.1. Responsibilities.

2.1.1. The trainee shall:

2.1.1.1. Ensure the trainer explains the Air Force Qualification Training Package (AFQTP) process and the responsibilities.

2.1.1.2. Review the AFQTP/Module/Unit with the trainer.

2.1.1.3. The trainee should ask questions if he/she does not understand the objectives for each unit.

2.1.1.4. Review missed questions with the trainer.

2.1.2. Instructor shall:

2.1.2.1. Review the AFQTP with the trainee.

2.1.2.2. Conduct knowledge training with the trainee using the AFQTP.

2.1.2.3. Grade the review questions using the answer key.

2.1.2.4. Review missed questions with the trainee to ensure the required task knowledge has been gained to complete the task.

2.1.2.5. Sign-off the task(s).

2.1.3. The Certifier shall:

2.1.3.1. Evaluate the Airman’s task performance without assistance.

2.1.3.1.1. The Performance Test will be successfully accomplished prior to initial certification on the forklift.

2.1.3.1.2. The Performance Test will be successfully accomplished, every three years, in order to be recertified on the forklift.

2.1.3.2. Sign-off the task(s).

Section 3—INTRODUCTION

3.1. Objectives:

3.1.1. Given lectures, demonstrations, review questions, hands-on driving session, and a performance and written test, trainees will be able to perform operator’s inspection and complete the performance test (go/no-go checklist) with zero instructor assists.

3.1.1.1. Train and qualify each trainee in safe operation and preventive maintenance of various forklifts.

3.1.1.2. This training will ensure the trainee becomes a qualified forklift operator; an operator who has the knowledge and skills to operate a forklift in a safe and professional manner.

3.2. Desired Learning Outcomes:

3.2.1. Understand the safety precautions to be followed before-, during-, and after-operation of the forklift.

3.2.2. Understand the purpose of the forklift and its role in the mission.

3.2.3. Understand Occupational Safety & Health Administration (OSHA) and Air Force Occupational Safety and Health (AFOSH) compliance requirements.

3.2.4. Know the proper operator maintenance procedures of the forklift, in accordance with (IAW) applicable technical orders and use of Air Force (AF) Form 1800.

3.2.5. Safely and proficiently operate the forklift.

3.3. Lesson Duration.

3.3.1. Recommended instructional and hands on training time is 40 hours:

Figure 3.1. Recommended Training Time for Training Activities.

Training Activity Training Time Trainee’s Preparation 2 Hours Instructor’s Lecture 2 Hours Trainee’s Written Evaluation 1 Hour Instructor’s Demonstration 4 Hours Trainee’s Personal Experience (to build confidence and proficiency) Perform Operator Maintenance Operate the Vehicle

30 Hours

Trainee’s Performance Evaluation 1 Hour

Note: This is a recommended time; training time may be more or less depending how quickly a trainee learns new tasks.

3.4. Instructional References.

3.4.1. Risk Management (RM) and Safety Principles.

3.4.2. Applicable Technical Orders (TOs) or Manufacturer’s Operator’s Manual (see vehicle maintenance for TO number for vehicle being used in training).

3.4.3. Air Force Manual (AFMAN) 24-306, Operation of Air Force Government Motor Vehicles.

3.4.4. AFMAN 91-201, Explosive Safety Standards.

3.4.5. Hazardous Materials Lesson Plan.

3.4.6. Regulations (Standards - 29 Code of Federal Regulations (CFR)), Part 1910 - Occupational Safety and Health Standards, Subpart N – Material Handling and Storage.

3.4.7. OSHA Directive, Enforcement and Compliance (CPL) 02-01-028 - CPL 2-1.28A - Compliance Assistance for the Powered Industrial Truck Operator Training Standards

3.4.8. AF Form 1800, Operator’s Inspection Guide and Trouble Report (General Purpose Vehicles).

3.5. Instructional Training Aids and Equipment.

3.5.1. Forklift Lesson Plan.

3.5.2. Forklift.

3.5.3. Applicable TO or Manufacturer’s Operator’s Manual.

3.5.4. AF Form 1800.

3.5.5. Videos (if locally produced).

3.5.6. Suitable training area.

3.5.7. Traffic cones or suitable markers.

3.5.8. Palletized loads or skids.

3.5.9. Tractor/Trailer combination and/or loading dock.

3.5.10. K-Loader, rollerized trailer, or aircraft (for aircraft loading).

3.6. Suggested Sources for Obtaining Supplemental Training Material.

3.6.1. J.J. Keller & Associates - www.jjkeller.com.

3.6.2. OSHA Training Online – www.free-training.com/osha/forklift/forkmenu.htm.

3.6.3. The Training Network - www.safetytrainingnetwork.com/products/forklift.shtml.

Section 4—TRAINEE PREPARATION

4.1. Licensing Requirements.

4.1.1. Trainee must have in his/her possession a valid state driver’s license.

4.1.2. AF Form 171, Request for Driver’s Training and Addition to U.S. Government Driver’s License IAW Air Force Instruction (AFI) 24-301, Ground Transportation.

4.1.3. Applicable local licensing jurisdiction requirements.

4.2. Required Reading.

4.2.1. Read Forklift Lesson Plan.

4.2.2. Read AFMAN 24-306.

4.2.3. Read Manufacturer’s Operator’s Manual for the vehicle being trained on.

4.2.4. Complete forklift operation review questions, Attachment 5.

Section 5—KNOWLEDGE LECTURE

5.1. Knowledge Overview (Lecture).

5.1.1. The AF uses a variety of different forklifts (also referred to as “powered industrial trucks”) to accomplish its mission, they range from small to large, from simple hand lifts to complex powered forklifts. Like any other vehicle, training and licensing is a requirement to ensure an operator can operate a forklift safely and proficiently. Forklift training, as required by OSHA, includes:

5.1.1.1. A combination of formal instruction and practical demonstrations and exercises.

5.1.1.2. A wide range of subjects and skills specified in the regulation.

5.1.1.3. Refresher training must be given under a variety of specific circumstances.

5.1.1.4. Operators shall be evaluated at least once every 3 years.

5.1.1.5. Required training shall be certified in writing.

5.2. Overview of Training and Requirements.

5.2.1. Training objectives:

5.2.1.1. Given lectures, demonstrations, review questions, hands-on driving session, and a performance and written test, trainees will be able to perform operator’s inspection and complete the performance test (go/no-go checklist) with zero instructor assists.

5.2.1.2. Train and qualify each trainee in safe operation and preventive maintenance of the various forklifts.

5.2.1.3. This training will ensure the trainee becomes a qualified forklift operator—an operator who has the knowledge and skills to operate a forklift in a safe and professional manner.

5.2.2. Desired learning outcomes:

5.2.2.1. Understand the safety precautions to be followed before-, during-, and after-operation of the forklift.

5.2.2.2. Understand the purpose of the forklift and its role in the mission.

5.2.2.2.1. Purpose is for cargo movement.

5.2.2.2.2. Role in the mission (Unit/Base/Community (during natural disasters)/Air Force).

5.2.2.2.3. Know the proper operator maintenance procedures of the forklift, IAW applicable technical orders and use of AF Form 1800.

5.2.2.2.4. Be able to safely and proficiently operate the forklift.

5.2.2.2.4.1. Meet mission requirements.

5.2.2.2.4.2. Demonstrates a qualified trained professional operator.

5.2.3. Forklift Design. Forklifts vary in size, shape and specifications, determined by make and model; it is imperative to know the specifications and rated loads of the forklift that will be operated before use. Specifications and rated load information should be used together to determine the proper use and area in which the forklift will be used. This information is best found in the appropriate TO or for quick reference, the information may be found on the vehicle data plate located on the forklift, see Figure 5.1. for an example of a forklift data plate.

5.2.4. While the discussion following will explain the general design of a forklift, it is recommended that the operator studies the manufacturer’s operator manual for the specifics of the forklift.

Figure 5.1. Forklift Data Plate Example.

5.2.5. Specifications. Specifications generally described are equipment dimensions/weight;

engine/drive train information; turning radius; and engine/drive train fluid types. Forklift specifications can be found on the vehicle’s data plate, and the Manufacturer’s Operator’s Manual or appropriate TO for the vehicle.

5.2.6. Rated Load/Capabilities. Rated loads and capabilities generally described are lifting capacity; load center; maximum reach; and maximum stacking height.

Note: Specifications given are for a centered and balanced load. Lifting the maximum amount of the forklift capacity when the load is not properly balanced could cause tipping of the forklift.

5.2.7. Forklift Parts. The make-up of a forklift differs by make and model, however all forklifts will have a counterweight, lifting mast, or device and overhead guard.

5.2.7.1. Counterweights. The counterweight on a forklift does exactly what its name implies; it counters, or opposes the forces of the load put on the forklift.

5.2.7.1.1. Counterweights come in many shapes and sizes. Some are removable or can be stacked/un-stacked to eliminate weight when small loads are being handled over soft terrain or for shipping purposes.

5.2.7.1.2. Most counterweights are rested into place and require little hardware to keep them in place. Therefore, it is in the best interest to ensure the counterweight is securely fastened to the forklift before operation. Figure 5.2. illustrates different styles of counterweights.

Figure 5.2. Forklift Counterweight Styles.

5.2.7.2. Lifting mast or device. Lifting devices on forklifts can be complicated or extremely simple. Lifting devices differ by make, model and function for which they are used.

5.2.7.2.1. Some forklifts in the AF inventory are equipped to rotate loads; some masts swing in and out, while other masts are boom style. There are many different models;

therefore it is imperative the trainee becomes fully trained on the model that the trainee is about to operate. One of the big differences in lifting devices is “reach”.

5.2.7.2.2. Standard forklifts lift loads straight up and down, while all terrain (AT) and other models of forklifts lift their masts at an angle and “reach” when raised. Figure

5.3. shows the difference in lifting device reach.

Figure 5.3. Lifting Device Reach.

5.2.7.3. Overhead guards. Overhead guards are put in place to protect the operator in case of falling objects and should the forklift tip over.

5.2.7.3.1. In the case of forklifts with cabs, the overhead guard is built into the cab itself. These also provide protection from the outside elements of the environment.

5.2.7.3.2. Some of these cabs are removable for shipping purposes, after shipment, these cabs should be put back in place before operation continues. Figure 5.4.

illustrates different styles of overhead guards.

Figure 5.4. Overhead Guards.

5.2.8. Forklift Steering and Speed Control.

5.2.8.1. Steering. The majority of forklifts utilize rear wheel steering or articulated steering. The ability of using rear wheel steering gives the operator more maneuverability for placing loads in the correct position and moving through tight warehouse locations.

5.2.8.1.1. Articulated steering is used mainly on all terrain forklifts, this function is best for all wheel drive equipment, as it requires less differential slipping. Of course these steering systems can take some time to get used to.

5.2.8.1.2. Having the rear wheel steering adds more areas that the operator needs to have good visibility. While turning the forklift, not only does the front of the equipment move, but the rear as well, adding to more possibilities of striking something.

5.2.8.1.3. Articulated steering gives the view of all moving parts in the same direction, as long as the equipment’s operator station is high enough with unrestricted visibility this is a benefit to the operator. Figure 5.5. illustrates different steering systems used on most forklifts, and the difference of front wheel steering.

Figure 5.5. Forklift Steering Systems.

5.2.8.2. Speed Control. Speed not only makes accidents more likely, but also makes death in accidents more likely. Never operate a vehicle at a speed greater than is reasonable and prudent under the existing conditions.

5.2.8.2.1. Speed affects the ability to turn, pass, slow down and stop. The most important safety factor in any vehicle is the control the driver has over the machine.

5.2.8.2.2. The faster the vehicle goes and the more of that control the driver gives up, the less chance the driver has of avoiding an accident and the more deadly the accident will be.

5.2.8.2.3. Accelerating. Gradually accelerate a forklift to minimize jerking. Rapid acceleration can cause mechanical failure and is considered vehicle misuse. Jerking and rapid acceleration also contributes to loads falling off the forks and adding unnecessary hazards to pedestrians around the vehicle.

5.2.8.2.4. Steering.

5.2.8.2.4.1. Normally, both hands are kept on the steering wheel while operating the forklift. During loading and unloading the left hand is used to steer while the right hand operates the hydraulic controls.

5.2.8.2.4.2. Remember to turn slowly; a forklift is unstable when the forks are elevated, with or without a load. Tip-over can occur when the forklift is empty.

Avoid turning on an incline. Watch tail swing when making turns observing rear clearances.

5.2.8.2.5. Stopping. Stop the forklift as gradually as possible. Hard braking and wheel sliding are unnecessary and may cause the load to fall off the forks, possibly damaging the load and/or hurting someone. The following factors affect the ability to bring the forklift to a stop:

5.2.8.2.5.1. Type and condition of road surface, such as concrete, asphalt, or gravel.

5.2.8.2.5.2. Foreign material on the road, such as ice, snow, leaves, water, or mud.

5.2.8.2.5.3. Road configuration, such as inclines, curves, high crowns.

5.2.8.2.5.4. Tire conditions, such as type, tire inflation, and condition of tread.

5.2.8.2.5.5. Brakes, such as type and state of repair and adjustment.

5.2.8.2.5.6. Load on forklift, an unloaded forklift will stop sooner and smoother than a loaded one.

5.2.8.2.6. Stopping Distance. For any speed, the distance required to stop a forklift in an emergency depends on three things; driver perception time, driver reaction time, and forklift stopping time. During driver perception time and driver reaction time, the forklift slows down very little because the brakes have not yet been applied. Forklifts equipped with air brakes take additional time because it takes the air time to travel through the system to engage the brakes. This is called brake lag.

5.3. Vehicle Inspection.

5.3.1. Types of Vehicle Inspection. Note: If discrepancies are found the operator must report them to Vehicle Control Officer/Vehicle Control Non Commissioned Officer (VCO/VCNCO), the supervisor, and/or vehicle maintenance:

5.3.1.1. Pre-trip inspection – find items/problems that could cause accident or breakdown.

5.3.1.1.1. Vehicle maintenance to authorize continued use for all other maintenance discrepancies.

5.3.1.1.2. Cleanliness/damage/missing items.

5.3.1.1.3. Leaks (fuel/oil/coolant/hydraulic/air).

5.3.1.1.4. Fluid levels; ensure level is within limits:

5.3.1.1.4.1. Engine oil.

5.3.1.1.4.2. Brake fluid.

5.3.1.1.4.3. Transmission fluid.

5.3.1.1.4.4. Antifreeze.

5.3.1.1.4.5. Hydraulic fluid.

5.3.1.1.5. Battery; security, fluid, damage, and corrosion.

5.3.1.1.6. All wheel rims (cracks, splits, etc.); check for loose or missing lug nuts.

5.3.1.1.7. All tires.

5.3.1.1.7.1. Proper inflation. Note: Notify VCO/VCNCO, the supervisor, and/or vehicle maintenance if split rim is completely flat.

5.3.1.1.7.2. Tread to include depth.

5.3.1.1.7.3. Cuts and abrasions.

5.3.1.1.8. Drive belts; tension, and fraying.

5.3.1.1.9. Air restriction gauge.

5.3.1.1.10. Carriage.

5.3.1.1.11. Hydraulic hoses/cylinders (damage/leaks).

5.3.1.1.12. Wiring/lights/reflectors/mirrors.

5.3.1.1.13. Safety devices.

5.3.1.1.14. Mast tines/roller tines.

5.3.1.1.15. Towing connection.

5.3.1.1.16. Markings – check visibility.

5.3.1.1.17. Horn operation.

5.3.1.1.18. Windshield wipers/washers.

5.3.1.1.19. Heater/defroster.

5.3.1.1.20. Exhaust system.

5.3.1.1.21. Brake and accelerator covers.

5.3.1.1.22. Air tanks.

5.3.1.1.23. Cold weather aids.

5.3.1.1.24. Emergency stand-by system.

5.3.1.1.25. Refill alcohol injector reservoir (in season).

5.3.1.1.26. Fire extinguisher(s).

5.3.1.2. During-operation:

5.3.1.2.1. All gauges and warning lights for proper operations.

5.3.1.2.1.1. Warning lights.

5.3.1.2.1.2. Gauges.

5.3.1.2.1.3. Indicators.

5.3.1.2.2. Forklift controls for proper operations.

5.3.1.2.2.1. Steering wheel.

5.3.1.2.2.2. Steering wheel tilt control.

5.3.1.2.2.3. Direction control lever.

5.3.1.2.2.4. Gear selector lever.

5.3.1.2.2.5. Parking brake control.

5.3.1.2.2.6. Hydraulic control levers, normal controls are lift/lower and tilt.

5.3.1.2.2.6.1. Lift/lower control lever.

5.3.1.2.2.6.2. Tilt control lever.

5.3.1.2.2.6.3. Side shift,

5.3.1.2.2.6.4. Fork positioning lever.

5.3.1.2.2.6.5. Other controls (rotate, swing, extend, etc.).

5.3.1.2.2.7. Off/on/enrich knob.

5.3.1.2.2.8. Battery disconnect switch.

5.3.1.2.2.9. Accelerator control pedal.

5.3.1.2.2.10. Ignition switch (glow plugs).

5.3.1.2.2.11. Service brakes/inching pedal.

5.3.1.2.2.12. Selector switch.

5.3.1.2.2.13. Selector gas or liquefied petroleum gas (LPG) for bi-fuel engines.

5.3.1.2.3. Unusual noises.

5.3.1.2.4. Listen for exhaust and air leaks.

5.3.1.2.5. All gauges and warning lights for proper operations.

5.3.1.2.5.1. Warning lights.

5.3.1.2.5.2. Gauges.

5.3.1.2.5.3. Indicators.

5.3.1.2.6. Forklift controls for proper operations.

5.3.1.2.6.1. Steering wheel.

5.3.1.2.6.2. Steering wheel tilt control.

5.3.1.2.6.3. Direction control lever.

5.3.1.2.6.4. Parking brake control.

5.3.1.2.6.5. Hydraulic control levers.

5.3.1.2.6.5.1. Lift/lower control lever.

5.3.1.2.6.5.2. Tilt control lever.

5.3.1.2.6.5.3. Side shift (if equipped).

5.3.1.2.6.5.4. Fork positioning lever (if equipped).

5.3.1.2.6.5.5. Other controls (rotate, swing, extend, etc.).

5.3.1.2.6.6. Off/on/enrich knob.

5.3.1.2.6.7. Battery disconnect switch.

5.3.1.2.6.8. Accelerator control pedal.

5.3.1.2.6.9. Ignition switch.

5.3.1.2.6.10. Service brakes/inching pedal.

5.3.1.2.6.11. Selector switch.

5.3.1.2.6.12. Selector gas or LPG for bi-fuel engines.

5.3.1.2.7. Unusual noises. Listen for exhaust and air leaks.

5.3.1.3. After-Operation Inspection.

5.3.1.3.1. Ensure the forklift is cleaned (free of dirt, excess oil, and grease).

5.3.1.3.2. Refuel.

5.3.1.3.2.1. For all types of fuel and charging: Use refueling area or charging area, turn-off engine and use parking brake, and do not smoke or use electronic devices.

5.3.1.3.2.2. Diesel or gasoline.

5.3.1.3.2.3. Compressed natural gas.

5.3.1.3.2.3.1. Ensure refueling hose is properly connected.

5.3.1.3.2.4. Propane.

5.3.1.3.2.4.1. Turn-off fuel valve at cylinder.

5.3.1.3.2.4.2. Let engine die to purge all liquid phase propane (LPP) from lines.

5.3.1.3.2.4.3. Disconnect cylinder and remove.

5.3.1.3.3. Battery charging.

5.3.1.3.3.1. Use eye protection when making connections.

5.3.1.3.3.2. Use manufacturer’s approved charger.

5.3.1.3.3.3. Have eye wash facilities available.

5.3.1.3.3.4. Have an acid neutralizing agent available.

5.3.1.3.3.5. Don’t over fill the batteries with water.

5.3.1.4. Pre-trip vehicle inspection test. Use Attachment 2 as a walk-around guide along with AF Form 1800.

5.3.2. A Seven-Step Inspection Method will help ensure the inspection is the same each time it is conducted, and that nothing is left out. See Attachment 4 for the Seven-Step Inspection Method.

5.4. Vehicle Safety and Equipment.

5.4.1. Hazards and Human Factors.

5.4.1.1. Common mishap types.

5.4.1.1.1. Dropped property.

5.4.1.1.2. Bruises, head injuries, cuts and lacerations to personnel.

5.4.1.1.3. Fatalities due to roll-overs.

5.4.1.2. Common operator mishap causes:

5.4.1.2.1. Jerky starts and stops.

5.4.1.2.2. Failure to give proper signals when turning.

5.4.1.2.3. Traveling too fast and turning too sharply.

5.4.1.2.4. Failure to sound horn at intersections or when entering or exiting a building.

5.4.1.2.5. Turning too wide on corners; cutting corners too sharply.

5.4.1.2.6. Forklift carrying loads too high when traveling (tines should not be higher than 6 inches above the working surface).

5.4.1.2.7. Lowering loads too fast; failure to ensure that a pallet load is properly balanced and stacked.

5.4.1.2.8. Failure to ensure that forks (tines) are fully under the load before lifting.

5.4.1.2.9. Striking the pallet or the floor with the forks.

5.4.1.2.10. Driving across bridge plates too fast and failure to observe load carrying capacity on bridge plates.

5.4.1.2.11. Positioning empty forks too high when traveling (no higher than 6 inches above the working surface).

5.4.1.2.12. Failure to release parking brake before traveling.

5.4.1.2.13. Driving forward when the load restricts vision.

5.4.1.2.14. Descending an incline with the load in front.

5.4.1.2.15. Pinch points on articulated steering systems.

5.4.1.2.16. Failure to secure load to the forklift over long distances.

5.4.1.2.17. Failure to use a spotter in difficult areas/situations.

5.4.2. Safety Clothing and Equipment:

5.4.2.1. Safety steel-toed boots must be worn.

5.4.2.2. Gloves will be worn during cargo loading and unloading (take off rings/jewelry first.

5.4.2.3. Reflective belts/vests during operation of low visibility and on the flightline.

5.4.2.4. Raingear, cold weather gear, etc. Note: Avoid operating an open operation forklift during the rain.

5.4.2.5. Hearing protection when utilizing a gas or diesel driven forklift without a properly installed cab with the door and windows closed.

5.4.2.6. AF Form 1800.

5.5. Driving Safety and Precautions.

5.5.1. Forklift Safety and Operator Maintenance. Ensure trainee understands the importance of these safety items and procedures. The following safety operations are directly from OSHA regulations, by abiding in these regulations and following RM processes operating a forklift can be accomplished without mishaps.

5.5.1.1. Do NOT drive a forklift up to anyone standing in front of a bench or other fixed object.

5.5.1.2. Do NOT stand, work, or pass under the elevated portion of any forklift, whether loaded or empty.

5.5.1.3. Personnel shall NOT be permitted to ride on powered forklifts.

5.5.1.4. Never place arms or legs between the uprights of the mast or outside the running lines of the forklift.

5.5.1.5. When a forklift is left unattended: fully lower forks, neutralize controls, shut-off power, and set brakes. Block wheels if the forklift is parked on an incline.

5.5.1.6. A forklift is unattended when the operator is 25 feet or more away from the vehicle which remains in his view or whenever the operator leaves the vehicle and it is not in his view.

5.5.1.7. When the operator of a forklift is dismounted and within 25 feet of the truck still in view: lower the load engaging means, neutralize controls, and set the brakes to prevent movement.

5.5.1.8. Maintain a safe distance from the edge of ramps or platforms while on any elevated dock, or platform or freight car.

5.5.1.9. Do NOT use forklifts for opening or closing freight doors.

5.5.1.10. Ensure sufficient headroom under overhead installations, lights, pipes, sprinkler system, etc.

5.5.1.11. Ensure an overhead guard is in place as protection against falling objects. An overhead guard is intended to offer protection from the impact of small packages, boxes, bagged material, etc., representative of the job application, but not to withstand the impact of a falling capacity load.

5.5.1.12. Use a load backrest extension whenever necessary to minimize the possibility of the load or part of it from falling rearward.

5.5.1.13. Only approved forklifts shall be used in hazardous locations.

5.5.1.14. Keep fire aisles, access to stairways, and fire equipment clear.

5.5.1.15. Observe all traffic regulations. Maintain a safe distance of approximately three forklift lengths from the vehicle ahead, and keep the forklift under control at all times.

5.5.1.16. Yield the right of way to ambulances, fire trucks, or other vehicles in emergency situations.

5.5.1.17. Do NOT pass other forklifts traveling in the same direction at intersections, blind spots, or other dangerous locations.

5.5.1.18. The driver shall be required to 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.

5.5.1.19. Cross railroad tracks diagonally wherever possible. Do NOT park closer than 8 feet from the center of railroad tracks.

5.5.1.20. Look in the direction of, and keep a clear view of the path of travel.

5.5.1.21. Ascend/descend grades slowly.

5.5.1.22. When ascending or descending grades in excess of 10%, drive loaded trucks with the load upgrade.

5.5.1.23. On all grades, tilt back the load and load engaging means, if applicable, and raise the load only as far as necessary to clear the road surface. Drive forward up a ramp and back down a ramp.

5.5.1.24. Operate the forklift under all travel conditions at a speed that will permit it to be brought to a stop in a safe manner.

5.5.1.25. Stunt driving and horseplay will NOT be permitted.

5.5.1.26. Slow down for wet and slippery floors.

5.5.1.27. Properly secure board or bridge plates before they are slowly and carefully driven over. Ensure their rated capacity never exceeded. Remove snow or ice.

5.5.1.28. Approach elevators slowly, and then enter squarely after the elevator car is properly leveled. Once on the elevator, neutralize controls, shut-off power and set brakes.

5.5.1.29. Motorized hand trucks must enter elevator or other confined areas with load end forward.

5.5.1.30. Avoid running over loose objects on the roadway surface.

5.5.1.31. While negotiating turns, reduce speed (braking) and steer in a smooth, sweeping motion. Except when maneuvering at a very low speed, turn the hand steering wheel at a moderate, even rate.

Note: Secure loads to the forklift when carrying bulky loads or traveling long distances.

5.6. Forklift Load Composition and Stability.

5.6.1. Definitions. The following definitions help to explain the principle of stability.

5.6.1.1. Center of gravity. The point on an object at which all of the object's weight is concentrated. For symmetrical loads, the center of gravity is at the middle of the load.

5.6.1.2. Counterweight. The weight that is built into the forklift’s basic structure and is used to offset the load's weight and to maximize the vehicle's resistance to tipping over.

5.6.1.3. Fulcrum Point. The point on the truck between which balances the weight of the truck and the weight of the load being carried. The forklift’s axis of rotation when it tips over is called the fulcrum.

5.6.1.4. Grade. The slope of a surface, which is usually measured as the number of feet of rise or fall over a hundred foot horizontal distance (the slope is expressed as a percent).

5.6.1.5. Lateral stability. A forklift’s resistance to overturning sideways.

5.6.1.6. Line of action. An imaginary vertical line through an object's center of gravity.

5.6.1.7. Load center. The horizontal distance from the load's edge (or the fork's or other attachment's vertical face) to the line of action through the load's center of gravity.

5.6.1.8. Longitudinal stability. The forklift's resistance to overturning forward or rearward.

5.6.1.9. Moment. The product of the object's weight times the distance from a fixed point (usually the fulcrum point). In the case of a powered forklift, the distance is measured from the point at which the forklift will tip over to the object's line of action. The distance is always measured perpendicular to the line of action.

5.6.1.10. Track. The distance between the wheels on the same axle of the forklift.

5.6.1.11. Wheelbase. The distance between the centerline of the vehicle's front and rear wheels.

5.6.2. General. Determining the stability of a forklift is simple once a few basic principles are understood. There are many factors that contribute to a vehicle's stability: the vehicle's wheelbase, track, and height; the load's weight distribution; and the vehicle's counterweight location (if the vehicle is so equipped). The "stability triangle," used in most stability discussions, demonstrates stability simply.

5.6.2.1. Basic Principles. Whether an object is stable depends on the object's moment at one end of a system being greater than, equal to, or smaller than the object's moment at the system's other end.

5.6.2.1.1. This principle can be seen in the way a see-saw or teeter-totter works: that is, if the product of the load and distance from the fulcrum point (moment) is equal to the moment at the devices other end, the device is balanced and it will not move.

However, if there is a greater moment at one end of the device, the device will try to move downward at the end with the greater moment.

5.6.2.1.2. The longitudinal stability of a counterbalanced powered industrial truck depends on the vehicle's moment and the load's moment. In other words, if the mathematic product of the load moment (the distance from the front wheels, the approximate point at which the vehicle would tip forward) to the load's center of gravity times the load's weight is less than the vehicle's moment, the system is balanced and will not tip forward. However, if the load's moment is greater than the vehicle's moment, the greater load-moment will force the truck to tip forward.

5.6.3. Physics/Stability. In order to safely operate a forklift one must understand the physical aspects of carrying a load.

5.6.3.1. If a load is not properly balanced on the forks, tipping of the forklift or dropping of the cargo can result. Loads will be of different shapes, weights and balance, it is imperative that correct load balancing is learned and practiced.

5.6.3.2. To better the understanding of how a load will carry it is also important to know where the Center of Gravity of the forklift is and the parts of the forklift that add to this.

5.6.4. Stability. Stability is the resistance to sudden change, dislodgement or overthrow. As one can guess the stability of the forklift is extremely important during operation.

5.6.4.1. The center of gravity, dictated by the forklift, load size and weight on the forklift are all contributing factors. Forklift stability is a function of three-point suspension (stability triangle), as indicated by Figure 5.6.

Figure 5.6. Center of Gravity.

5.6.4.2. This stability triangle is formed by the drive axle tread of the forklift and the center point mount on the steering axle. Each vehicle has an imaginary stability triangle, an area of the vehicle in which the center of gravity must remain.

5.6.4.3. If the center of gravity shifts out of this triangle, handling characteristics diminish and tipping can follow. Refer to Figure 5.6. for the remainder of this paragraph.

5.6.4.4. Point D is the center of gravity of an empty forklift at rest on level ground. Point F is the center of gravity of the load, and point E is the combined center of gravity of the forklift and load. The combined center of gravity (point E) is with the triangle formed by points A, B, and C when the mast is vertical. Stability depends upon how close point E comes to the edge of the triangle. As this point approaches, or exceeds, the triangle’s boundary, the truck will tip.

5.6.4.5. Remember that stability is not only a forward and backward concern. As the center of gravity of the load is moved from left and right, the stability of the forklift is also.

5.6.4.5.1. The concern here is that forklifts are longer than they are wide; the same goes for the stability triangle. Tipping to the front is not as common as tipping to the side.

5.6.4.5.2. This can happen due to poor handling practices (turning too hard and fast) and poor load planning (placing heavier object to the right or left). At all times the center of gravity of the load and forklift must remain in the stability triangle.

5.6.5. Load Handling. The capacity of a forklift is given by weight and distance to the load center. This information is listed on the forklift data plate.

5.6.5.1. Before attempting to lift a load, make sure the weight is within the capacity of the forklift at the load center involved. Also, the rated capacity presumes that the center of the load is no further from the top of the forks than it is from the face of the carriage.

5.6.5.2. If these conditions do not exist, the operator may have to reduce the load weight since the center of gravity may be out of the stability triangle. See Figure 5.7. for illustration of load center and example.

Note: Forward tipping can be caused by, loads that exceed the rated capacity, excessive forward tilt with the load elevated, or by abrupt stopping while the load is elevated.

Figure 5.7. Forklift Load Center.

5.7. Forklift Loading and Unloading.

5.7.1. Loading and Unloading Safety. The following are safe practices to be observed when loading and unloading include:

5.7.1.1. Only handle stable and safely arranged loads. Exercise caution when handling off-center loads which cannot be centered.

5.7.1.2. Only handle loads within the rated capacity of the forklift.

5.7.1.3. Adjust the long or high (including multiple-tiered) loads which may affect capacity.

5.7.1.4. Operate forklifts equipped with attachments as partially loaded forklifts when not handling a load. Use only attachments issued with the forklift or approved by the forklift manufacturer.

5.7.1.5. Place the forks a load engaging means under the load as far as possible so that the load is up against the mast; the mast shall be carefully tilted backward to stabilize the load.

5.7.1.6. Use extreme care when tilting the load forward or backward, particularly when high tiering. Tilting forward with load engaging means elevation is prohibited except to pick up a load. An elevated load will not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering, only use enough backward tilt to stabilize the load.

5.7.2. Preparing Loads. The operator may be tasked to prepare the load or transport it. Either way as an operator moving the load, once the operator receives the load, the load becomes their responsibility. It is therefore imperative to know if the load is ready for transport or not.

5.7.2.1. Cargo comes in all shapes and sizes, however there are requirements for all.

Whenever possible, place cargo on pallets for stability.

5.7.2.2. There are hundreds, if not thousands, of different types of pallets and containers, however, in the AF most cargo will be packaged on skids, 463L pallets or self-contained (KITS pallet). These self-contained loads will vary as per the packaging requirements.

Self-contained loads require less prepping as long as they have been properly assembled and loaded. See Figure 5.8. for different styles of loads.

Figure 5.8. Forklift Load Styles.

5.7.2.3. Loads will always be tightly packed to reduce shifting and secured to the pallet before transport. Utilize cargo nets, cargo straps, chains, or multiple layers of plastic wrap/straps for lighter loads to secure the load to the pallet.

5.7.2.3.1. When the load must be placed outside during inclement weather, loads should be covered with tarpaulin for protection

5.7.2.3.2. Loads traveling over-the-road require different load preparation than loads traveling on military airlift. Contact Traffic Management Office (TMO) for further details and instructions.

Figure 5.9. Properly/Improperly Loaded Pallet.

5.7.2.4. Spotter. Generally, standard forklifts have a diminished view of the working area in front of the operator. Utilization of a spotter during loading and unloading of cargo is necessary to ensure the ability to see where the vehicle is going.

5.7.2.4.1. If visual contact with the spotter is lost, the spotter is dangerously positioned, or the operator is in doubt, the operator must immediately stop the vehicle.

5.7.2.4.2. Hand signals are often used to communicate between the spotter and the operator, if ever in doubt on what the spotter is trying to communicate, the operator should stop immediately and clarify with the spotter the meaning of the hand signal(s).

Standard AF forklift-specific hand signals are pictured below. See Figures 5.10. –

5.19. Refer to AFMAN 24-306 for additional standard AF spotter hand signals.

Figure 5.10. Forklift Hand Signals – Close/Open Fork Tines.

Figure 5.11. Forklift Hand Signals – Side Shift Right/Left.

Figure 5.12. Forklift Hand Signals – Raise/Lower Carriage.

Figure 5.13. Forklift Hand Signals – Tilt Mast Forward/Back.

Figure 5.14. Standard Spotting Hand and Arm Signals – Come Towards the Spotter.

Figure 5.15. Standard Spotting Hand and Arm Signals – Move Away from the Spotter.

Figure 5.16. Standard Spotting Hand and Arm Signals – Right/Left Turn.

Figure 5.17. Standard Spotting Hand and Arm Signals – Slow Down.

Figure 5.18. Standard Spotting Hand and Arm Signals – Stop.

Figure 5.19. Standard Spotting Hand and Arm Signals – Shut Down.

5.7.2.5. Picking Up Loads. When approaching a load to pick it up; move in slowly, ensure the forklift is square and centered with the load and the forks are at the proper height for engaging the load. Move slowly until the forks are entirely under the load.

5.7.2.5.1. Forks should be spread according to the load width for the maximum stability on the forks. Ensure to not over extend the forks and damage a load behind the one being approached. Forks should be longer than the load, after picking up the load, inch back, lower the load and fully rest the load against the carriage. Raise the load from the surface and tilt back just enough to safely carry it.

5.7.2.5.2. If the load is stacked, slowly back the forklift clear of the stack and lower the forks to a safe traveling height. During loading of cargo it is the best practice to utilize a spotter in tight or low visibility areas. The forklift mast blocking the operator’s view of the forks and load can cause low visibility.

5.7.2.6. Transporting Loads.

5.7.2.6.1. To transport a load, tilt the mast back just enough to travel safely. Do not raise the load higher than what is necessary for adequate floor clearance.

5.7.2.6.2. Travel in reverse in standard forklifts at all times with or without a load.

5.7.2.6.3. Travel forward in all terrain forklifts, unless visibility is impaired. If visibility is impaired, travel in reverse.

5.7.2.6.4. Avoid any sudden starts, stops and turns.

5.7.2.6.5. Ensure the load does not exceed the limitation of the forklift, and when starting to transport the load keep in mind the load may exceed the height and width of the forklift.

5.7.2.6.6. Forklifts should not be used to transport cargo over long distances or through heavy traffic areas. It is better to load the cargo on a tractor/trailer, pickup, stake & platform truck, etc. for transport and then use a forklift at the distant end to download the cargo. Pallets should be secured to the forklift when this is not possible.

5.7.2.7. Unloading. To unload on the floor, level the load with the floor and lower into place. It may be necessary to tilt the forks forward to remove the load smoothly.

5.7.2.7.1. Back out of the load. When backing out of the load, ensure the back portion of the forks are not in contact with the floor; this can damage the carriage keepers, eventually causing them to break.

5.7.2.7.2. To place the load on a stack, raise the load as the vehicle is inching into position. Be careful not to collide with adjacent loads. Once the load is square with the stack, level the load and lower the forks just enough to free them from the pallet, be careful not to drag the forks. Back away from the load and lower the forks as soon as the vehicle has cleared the stack.

5.7.2.7.3. When unloading 463L or KITS type pallets place load on shoring (dunnage).

Shoring (dunnage) provides a space for the forks to easily move in and out from underneath the load and keeps the pallets clean and dry. Utilize at least three pieces of shoring (dunnage) for each pallet to prevent warping of the pallet.

5.8. Forklift Operation.

5.8.1. Operating Inside and Outside of Warehouses. Observe the following items when operating in and out of warehouses:

5.8.1.1. Speed limit inside a warehouse is 5 miles per hour (mph).

5.8.1.2. Stop between 5 and 10 ft., sound horn prior to entering all warehouse openings/adjacent rooms

5.8.1.3. Warehouse ramps/Loading docks: Ensure gear selection is correct for safe operation in and out of buildings and prior to exiting ramps. Forklifts will be downshifted to “L” or low prior to descending or ascending ramps.

5.8.1.4. Only approved forklifts may be operated in warehouses with hazardous material.

5.8.1.5. Operate fuel (gas, diesel, propane, compressed natural gas) powered forklifts in approved ventilated warehouses

5.8.2. Forklift Attachments Use.

5.8.2.1. Two of the most common attachments that can be encountered on a forklift are rollerized tines and a personnel lift platform.

5.8.2.2. Rollerized Tines. Rollerized tines are used to unload rollerized trailers, rollerized docks, and aircraft during contingency operations. This accessory simplifies some tasks but at the same time adds to hazards.

5.8.2.2.1. When rollerized tines are issued with the forklift, these will be added to pre-inspections and preventive maintenance procedures. Rollerized tines will be turned in to transportation with the forklift for scheduled maintenance.

5.8.2.2.2. Rollerized tines will only be utilized on forks of the same size and capability as the forklift they are issued with. Rollerized tines will not be utilized as fork extensions at any time.

5.8.2.2.3. Do not utilize rollerized tines for SKID type pallets.

5.8.2.2.4. Lay the tines on a level floor and slowly drive into them. Do not lift the tines onto the forks.

5.8.2.2.5. Ensure rollerized tines are mechanically secured to the forks.

5.8.2.2.6. Whenever a load is placed on the rollerized tines, the load must be secured to the forklift.

5.8.2.2.7. Use rollerized tines only when necessary and for the shortest distance needed.

5.8.2.2.8. When stored, rollerized tines will be kept in the work area and not present a tripping hazard.

5.8.2.3. Personnel Lift Platform. Whenever a forklift is equipped with vertical controls only, or vertical or horizontal, the following additional precautions shall be taken for the protection of personnel being elevated:

5.8.2.3.1. Use of safety platform firmly secured to the lifting carriage and/or forks.

5.8.2.3.2. Means shall be provided whereby personnel on the platform can shut off power to the forklift.

5.8.2.3.3. Protection from falling objects as indicated necessary by the operating conditions shall be provided.

5.8.2.4. Parking. Parking of a forklift has a few more added requirements than parking a vehicle. Never leave the forklift in a condition that can cause damage and injury. Do not park a forklift so that it limits access to fire aisles, stairways and fire equipment. To park a forklift:

5.8.2.4.1. Find a level area to park the forklift.

5.8.2.4.2. Stop the forklift, place transmission control in neutral and apply the parking brake.

5.8.2.4.3. Lower the carriage completely; tilt the mast forward until the fork tips touch the ground.

5.8.2.4.4. On a forklift with a turbo-charged engine, let the engine idle for 5 minutes.

5.8.2.4.5. On a forklift without a turbo, let the engine idle according to manufacturer’s recommendation.

5.8.2.4.6. Turn-off all lights and accessories.

5.8.2.4.7. Turn ignition switch to the OFF position.

5.8.2.4.8. If applicable turn the master switch to the OFF position.

5.8.2.4.9. If the forklift must be parked on an incline or flightline, chock the drive wheels.

5.8.2.4.10. Drain air tanks if applicable.

5.8.2.4.11. Perform a walk around inspection of the forklift.

5.8.2.5. Flightline Rules and Regulations. Refer to AFI 13-213, Airfield Driving and

AFMAN 24-306.

5.8.2.5.1. Flightline training will be conducted separately.

5.8.2.5.2. General rules while operating on the flightline:

5.8.2.5.2.1. Do not exceed 5 mph around aircraft.

5.8.2.5.2.2. Do not load/unload while aircraft is being serviced with fuel or oxygen, unless concurrent servicing is authorized.

5.8.2.5.2.3. Utilize spotter when approaching or moving away from aircraft.

5.8.2.5.2.4. Place pre-positioned wheel chocks between aircraft and forklift.

5.8.2.5.2.5. Parking on flightline:

5.8.2.5.2.5.1. Place transmission control in neutral.

5.8.2.5.2.5.2. Apply the parking brake.

5.8.2.5.2.5.3. Lower the carriage completely (tilt the mast forward until fork tips touch ground).

5.8.2.5.2.5.4. Turn ignition switch to the OFF position.

5.8.2.5.2.5.5. Chock the drive wheels.

5.8.2.5.2.5.6. Leave key in ignition.

5.8.2.5.2.6. Forklift has proper lighting to include beacon light and/or flashers.

5.8.2.6. Fire Extinguisher Training. Most forklifts are equipped with fire extinguishers, which mean training is required. The supervisor or Squadron VCO will schedule training with the local Fire Department. Fire extinguisher training is an annual requirement after initial forklift training.

5.8.2.6.1. The fire extinguisher itself must be inspected to ensure current inspection date, ensure needle is positioned in the green and ensure it is securely mounted.

5.8.2.6.2. Ensure forklift is equipped with appropriate number of rated fire extinguishers (see AFMAN 91-201 for specific requirements concerning transport of explosive on a forklift).

5.8.2.7. Hazardous Materials. Personnel who transport explosives and hazardous material will receive separate training. The trainee must receive this training prior to transporting any hazardous materials.

5.8.2.8. Workplace Policies and Procedures. Ensure the trainee understands local policies and procedures in regards to forklift operations. If the trainee is at a temporary duty location, take the time to learn the policies and procedures for the location the vehicle is at.

Section 6—EXPLANATION AND DEMONSTRATION

6.1. Instructor’s Preparation.

6.1.1. Establish a training location.

6.1.2. Obtain appropriate Manufacturer’s Operator’s Manual.

6.1.3. Schedule/reserve a vehicle.

6.1.4. Ensure trainee completes AF Form 171.

6.2. Safety Procedures and Equipment.

6.2.1. The following safety items should be followed by both the instructor and trainee.

6.2.1.1. Chock wheel (if required) when forklift is parked.

6.2.1.2. Remove all jewelry and identification tags.

6.2.1.3. Personal protective equipment and equipment items.

6.2.1.3.1. Safety steel-toed boots must be worn.

6.2.1.3.2. Gloves will be worn during cargo loading and unloading.

6.2.1.4. Walk-around vehicle to familiarize the trainer and the trainee with all warning labels and signs.

6.2.1.5. Ensure trainee wears seat belts.

6.2.1.6. Properly adjust driver’s seat and all mirrors, if available.

6.2.1.7. Throughout demonstration, practice forklift safety:

6.2.1.7.1. Always observe speed and safety precautions while carrying loads.

6.2.1.7.2. Keep loads within the rated capacity of the forklift.

6.2.1.7.3. Travel with the forks raised no more than 6 inches from floor or ground.

6.2.1.7.4. When moving loads that obstructs view, travel in reverse.

6.2.1.7.5. Do not extend hands and arms through mast of forklift.

6.2.1.7.6. Only the operator is allowed to ride on the forklift.

6.2.1.7.7. Following other vehicles, allow at least three vehicle lengths.

6.2.1.7.8. Proper overhead clearance…