A forklift with a diesel engine is usually chosen for its fuel efficient design, exceptional lifting capacity, and longevity. The unique engineering with which a diesel motor is constructed creates its primary strength. Diesels use a motor’s own compression to ignite the fuel instead of spark plugs. Because of their distinctive design, a diesel power plant has a high torque output thereby producing an abundance of muscle to lift heavier loads. Diesel engines are notorious for their power, and they tend to remain in operation for extended periods of time. Many years of service can be expected from a diesel powered forklift. Their versatility makes them perfect for a variety of functions. There is not a forklift on the market that is more suitable for relocating extreme loads in the outdoors.

A diesel powered industrial lift truck has a few drawbacks related to that which gives this workhorse its dynamic competence and stamina: the diesel engine. Power of this magnitude comes at the expense of risky emissions, heavier construction and the ability to store reserve fuel. While improvements are constantly being made, diesel exhaust remains the most polluting of any forklift. The thicker fumes that are expelled tend to be more harmful and generally more annoying than trucks with other power sources. The heavier build needed to deliver this kind of leverage causes a diesel forklift to be weightier than other models. Also, additional expense for on-site fuel storage may need to be considered when operating diesel equipment.

Rising fuel prices and environmental concerns have encouraged many forklift owners to make the switch to electric trucks. While battery power delivers substantial savings – especially in the current financial climate – these can quickly be lost by poor battery care.

A typical forklift battery is worth up to 30% of a new truck’s value and offers you approximately 6,000 working hours. It is your fuel for the next five years or more… providing you look after it according to the manufacturer’s maintenance guidelines.

It is usually an engineer’s responsibility to maintain the battery and its charging equipment, but it is often the truck operators responsibility to carry out the simple day-to-day tasks involved in battery care.

General Safety Points

• Do not smoke in the charging area and never use a naked flame as a light when checking batteries.
• The battery cells contain acid, therefore a supply of water (clean) must be available so that should a person come into contact with the acid it can be washed off immediately.
• Disconnect the battery from the truck or the charger before commencing any maintenance inspection of the battery.
• Make sure that loose objects such as tools, or metal wrist straps cannot accidentally fall onto or come into contact with the top of the battery.
• Before opening the vent caps, personal protective equipment (PPE) such as goggles, rubber gloves and rubber/plastic apron must be worn.

Charging procedure

 At the end of the day or shift the battery will generally require charging.

• Disconnect the battery from the truck and lift the cover. Once you have put on your PPE, check the electrolyte levels in the cells, the liquid should completely cover the plates.  Top up if necessary with distilled water until the plates are just covered.  Dry off any spillage immediately and ensure all cell tops are replaced.
• Ensure the charger is switched off, and examine the charger cable and plugs for damage, then connect the charger cable plug to the battery plug.
• Switch on the current and ensure that the ammeter is registering the charge current.
• When disconnecting the battery on completion of charge switch off the charger before disconnecting the charger lead from the battery. Hang the lead up off the floor.
• Ensure the battery tops are dry and cell tops are secure. Connect the battery to the truck and replace the cover.
• IMPORTANT: When batteries are charging a slight amount of hydrogen gas is produced.  This is highly flammable.  The cover must remain open when charging is in progress to allow this gas to disperse harmlessly into the atmosphere.

Electric Forklift trucks provide the most ecological and economical advantages while being perfectly suited for duty in a warehouse type situation. An electrically powered lift truck does not produce fumes or harmful emissions of any sort. Since natural resources are limited and electricity is not, battery-powered lift trucks are cheaper to operate over an extended period of time. Because of their practically silent motor and their lack of exhaust fumes, electric forklifts are the most appropriate choice for indoor operations. They are ideal for use in cold storage facilities because they do not produce much heat, and they save money by not placing additional strain on warehouse temperature-control units.

The disadvantages of electric forklifts are notable, but many find the benefits to outweigh the negative aspects. Most of the drawbacks to an electric lift truck are related to battery charging issues. It requires a significant amount of down time to keep these power sources prepared for operation. When the weather is good and the surface upon which the truck must operate is without significant flaws, a battery-powered truck can operate outdoors. A forklift with an electric motor is capable of meeting most material handling conditions; nevertheless, those that use an internal-combustion engine can usually provide more power to lift heavier loads.

Most electric trucks nowadays will come with an option to purchase spare batteries and these can be on charge while the truck is being used.  At the end of a shift the operator can simply exchange the used battery for a fully charged one and the truck is ready for the next shift.

We all wear seatbelts whist driving our vehicles on the road but operators do not always wear their seatbelt while operating their forklift.

 
Most passenger vehicles come equipped with 3-point seatbelts, a soft impact dash, a collapsible steering column, air bags, impact bumpers, crumple zones, 4-wheel anti-lock brakes, doors, roof and radial tires. That’s a lot of safety equipment but we still understand the need to wear a seatbelt.

Now, let’s take a look at the average forklift truck:

• Solid steel rod steering column
• plastic-coated steel dash
• two wheel drum brakes
• open cab
• no crumple zones or bumpers

Although a forklift’s maximum speed is just 10-20 mph, you wouldn’t want to run into a wall at that speed! Even at just 10 mph, your hands will not be able to stay on the steering wheel. Your chest and/or abdomen will impact the steering column, and forward momentum will allow your legs to impact the solid-structure dash. Ultimately you are likely to be thrown from your seat, colliding with the mast assembly.

If your forklift is involved in a tip-over accident, you stand a good chance of being thrown from the operator’s seat and being crushed by the overhead guard. Remember, the overhead guard is there to provide protection from falling objects, it is not a roll cage and in the case of a tip-over accident, it can be deadly.

More than half of all forklift-related accidents involve either an impact or a tip-over/fall from the operator’s compartment.  It therefore makes sense to wear seatbelts when fitted on a lift truck.

Below is the HSE’s  position on wearing seatbelts whilst driving lift trucks:

“Since 2002, counterbalanced trucks, rough-terrain trucks and side-loading trucks, one side only, must be fitted with an operator restraining system (for example a seat belt). For older trucks which do not have one, you should fit a restraining system if the risk assessment indicates that there is a risk of the vehicle overturning and where the operator may be trapped between the truck and the ground. Where restraining systems are fitted they should be used.

Where a restraining system cannot be fitted, and the risks are sufficiently high, it will be necessary to use another lift truck which has such a system. Any lift truck fitted with a roll-over protective structure (ROPS) to protect operators from the risk of injury resulting from 180° or more roll-over should be fitted with a restraining system”

At the end of last month, we were delighted to be training back in Launceston, Cornwall.   Having lived near Launceston for five years, it brought back some good memories of lazy days on the beach at Crackington Haven and walks on Bodmin Moor and along Plymouth Hoe.

There are two main industrial estates in Launceston – the Newport Industrial Estate, where we were training, and the Pennygillam Industrial Estate.  Newport Estate is a large industrial site that is home to a range of local, regional and national businesses. The Pennygillam Industrial Estate is a popular mixed use estate, which is close to Launceston’s retail park, and has a good mix of local companies, as well as national operators such as City Electrical Factors, Plumb Centre, ATS and DHL.

Launceston was once the capital of Cornwall and it is easy to see why especially when you catch sight of the Norman Castle dominating the skyline as you approach the town. Situated close to the Devon border and within the picturesque Tamar Valley this once strategic stronghold has retained much of its ancient origins.

Set amidst rolling countryside Launceston is conveniently situated between Dartmoor and Bodmin Moor and within easy reach of the north and south Cornish coasts. It’s the perfect location from which to explore the rest of Cornwall as well as nearby north and west Devon.

Unfortunately there wasn’t time to visit the coast but we hope to be back in the area later in the year and may even stay on for a day or two if the weather is good! 

We are excited to be training at Milton Park this month, a premium business park in the South East of England (www.miltonpark.co.uk).

It’s more like a small town than a business park as it provides everything you need in one place:

• A Health and Fitness Centre
• Business Lounge
• Café
• Restaurant
• Nursery
• Post Office
• Meeting Rooms
• Hair and Beauty
• Convenience Stores
• Bike Hire
• Urban Garden
• Cash Machines
• Electric Car Charging

Milton Park is easily accessible by car just off the A34 south of Abingdon or alternatively you can reach the Park on the dedicated shuttle bus that runs from Didcot Parkway railway station.   Didcot Parkway is only 5 minutes away by bus and this provides fast connections to London Paddington, Oxford, Reading, Swindon and Bath.   We hope to be visiting again soon to provide training to some more of the many innovative business enterprises located on the business park.

If you would like us to visit your premises to assess your training requirements, please call us on 0800 024 8084 or e-mail info@stackerstraining.co.uk

The Health and Safety Executive (HSE) has released a new report following an assessment of forklift truck reverse sensor systems.  The report discusses the use of counterbalance lift trucks within a wide variety of industry sectors and how the vast majority of incidents involving lift trucks typically involve vehicle to pedestrian, vehicle to vehicle or vehicle to structure collisions.  Training helps to instil the importance of using certain measures to enhance an operator’s field of vision such as mirrors and reverse sensor systems which are similar to those used within passenger vehicles.  The investigation completed by the HSE delved into the use of active sensor systems to see how they affected, if at all, the risk of collisions with lift trucks in the work place.  The HSE concluded that reverse sensor systems provide a useful function to operators in reducing the risk of collision when mounted correctly onto the truck so there is a sufficient detection zone whilst avoiding false areas of detection.

We say ……. there is no better detection system than looking where you are going when reversing a lift truck.  We teach operators to turn round in their seat and look before moving in reverse and whilst continuing to move in reverse.  If the operator is reversing and turning then we encourage the operator to turn and face the way the truck is moving which is a great aid to vision.  Mirrors, reverse bleepers, flashing lights and sensors are all there to help the forklift operator but looking where you are going at all times is the best way of avoiding collisions.  Having said this, once operators are trained and start using the trucks in their own workplace there should be sufficient control measures to ensure that operators continue to drive safely.

Managers should be aware of the requirements of forklift drivers and although they do not have to be trained operatives they should be mindful of the difficulties and responsibilities that forklift operators face in their daily routine.  We can offer a one day Forklift Appreciation/Awareness course for Managers and Supervisors and for more information on this please call us on 0800 024 8084 or e-mail info@stackerstraining.co.uk.

Two company owners have been given suspended sentences after a worker was hit by building supplies which fell from a forklift truck.

For the full story click on the link below:

https://www.rtitb.co.uk/news/suspended-sentence-for-lift-truck-safety-breaches

The following guidelines should be followed in respect of loads:

Always

• Understand your truck’s load plate and lifting capacity.
• Ensure there is enough space to operate the truck with a load and don’t forget to check for overhead obstructions.
• Lift and lower loads smoothly and at an appropriate speed.
• Use suitable attachments for lifting unusual or wide loads and follow the manufacturer’s instructions.
• Ensure you are properly trained, competent and authorised to operate the lift truck with the attachment being used.

Never

• Lift loads greater than the capacity of the lift truck.
• Move a load that appears unsuitable or unstable (including on a damaged pallet).
• Travel with a bulky load which blocks your view.
• Travel with a raised load, unless the lift truck is designed for this.
• Use an attachment unless an authorised dealer or manufacturer has derated the lift truck (reduced the actual capacity) to ensure the lift truck operates within its safe working parameters.

If you need any advice about the lifting capacity of your truck, please call Stackers Training on 0800 024 8084.

• Ensure that forklifts are serviced regularly otherwise the cold and wet weather could lead to increased component failures.  Batteries, hydraulics and electrical systems become ever more important and engines need protection from cold weather.

• Ice or rain may create slippery surfaces outside so training drivers to be more cautious with their speed and supervision where necessary will help to reduce some safety risks.

• If a forklift operates in a muddy environment, it is important to regularly clean the equipment to prevent parts becoming blocked or clogged.

• Check the condition of the forklift’s tyres to ensure traction and stability in icy, wet conditions.  Gritting yard areas in the snow and freezing conditions will help to maintain traction.
• Ensure forklift drivers are doing their daily checks.

• Ensure there is a reliable, experienced forklift service provider looking after your trucks who can provide you with efficient support 24 hours a day in any weather.

• Check the security and stock level of the truck’s fuel supply in case supply is delayed or restricted due to snow.

If you would like any advice about operating your forklift in adverse weather conditions, please call us on 0800 024 8084.

To support productivity in the food and drink sector, RTITB (Road Transport Industry Training Board) is offering advice on how to improve the efficiency of forklift truck operations specifically in cold store environments.

The article which can be found by clicking on the link below outlines the following steps:

https://www.rtitb.co.uk/news/blogs/8-steps-for-efficient-cold-store-forklift-operations

1. Selecting the right equipment
2. Parking outside the cold room
3. Choosing the maximum nominal capacity battery for the size of the truck
4. Charging batteries correctly (and keeping them charged)
5. Conducting more regular maintenance
6. Ensuring pre-use checks take place
7. Delivering the right level of training
8. Providing operator comfort