Pallets and Boxes

Most of the loads that you will handle are on pallets or in boxes. A standard pallet is 40 inches by 48 inches, as shown in figure 8-20. Mount-out boxes are in all different sizes; however, they have stringers like pallets.

LIFTING.- The technique for lifting a pallet is as follows:

1. Position the forklift squarely in front of the load and raise the forks to the proper level, halfway between the top and bottom boards of the pallet.

2. Slowly insert the forks into the pallet until the load rests against the fork faces. If the mast is not in a vertical position, the forks may hang up in the pallet when they are inserted.

NOTE: If the pallet or load is against a wall or obstruction and the forks are longer than the pallet, you will have to pick up the pallet and back up the forklift until there is enough room to reposition the forks entirely under the pallet.

3. Lift the load just enough to clear the floor (or stack beneath the load being removed). Then tilt the mast or forks back enough to cradle the load. The load should always be carried as low as possible for maximum stability and vision.

Figure 8-20.-40- by 48-inch pallet.

WARNING

Overloading a forklift is strictly prohibited. The forklift can safely lift and carry no more than its rated capacity. Among the dangers of overloading are injury to the operator, damage to the cargo, and damage to the pump and lift mechanism. Additionally, overloading causes wear on the tires, engine, _{or electric motor.} Also, a forklift will tip forward if the load on the forks exceeds the lift capacity of the forklift. The manufacturer has established the forklift rating (expressed in pounds of load on the fork) and the allowable distance in inches from the heel of the forks to the center of gravity of the load. This distance is known as the load center.

CARRYING.- Carrying material with a forklift to move it from one location to another requires skill and concentration. The techniques for carrying loads with a forklift are as follows:

1. Tilt the mast as far back as the load will permit when carrying a load, and raise the load only high enough to clear obstructions. Always change speed gradually, as sudden starts and stops will cause the load to shift. Gradual starts and stops also prevent rapid wear of equipment components.

2. Always know the ground clearance of your forklift truck and the surface you are traveling on.

NOTE: If the load is so bulky that your vision is obstructed, drive in reverse. Extra care must be taken when driving in reverse, because the operator does not have a constant view of the load; therefore, a backing guide is usually needed.

3. You should ascend and descend a grade with the load pointing upgrade when operating a loaded forklift on an incline (fig. 8-21). Normally, direction of travel should be determined by what direction the operator can see best. This is why forklifts are built with reverse as well as forward travel. But, on grades of 10 percent or more, both forklift and load stability demand that the load be kept upgrade.

4. Handle each load within the rated capacity of the forklift. The rated capacity is the weight the forklift can handle safely. The forklift data plate rating indicates the maximum safe load that can be lifted. This maximum rating should never be exceeded; however, there are conditions requiring a load less than the rated capacity. The data plate rating does apply for weak

Figure 8-21.-Direction of travel on a grade.

floors, uneven terrain, special load-handling attachments, or loads with a high center of gravity. Under these conditions, the safe working load is well below the rated capacity. Under special conditions, you must reduce your load so your forklift will remain stable.

5. Handle only stable loads. Many loads are made up of unstable items that can be easily dislodged. This rule is critical to your safety when the forklift is not equipped with an overhead guard or roll over protection structure (ROPS).

6. Center the weight of wide loads between the forks; otherwise, the load may topple off the forks when you turn a corner or hit a bump.

7. Watch "swing" when handling long loads. Failure to watch clearance at the ends of your load can cause you to strike persons or objects.

8. Keep the load against the carriage by maintaining a slight backward tilt.

9. Do not travel with the load raised higher than 6 inches from the floor until you are ready to deposit the load. When loads are carried in an elevated position, the stability of the forklift is reduced. The load or part of it can fall on someone or something.

10. Drive carefully, observe traffic rules, and be in full control of the forklift at all times.

POSITIONING.- When loading and stacking material, move the forklift truck forward until the load arms are entirely under the load to be lifted. Ensure the load is centered on the arms and that it is well-seated against the face of the lifting carriage. When picking up round objects, first tilt the uprights so the forks slide along the floor or ground under the object to be lifted, as shown in figure 8-22. Then decelerate, tilt backwark, and accelerate until there is enough backward tilt of the mast to allow safe handling of the load.

NOTE: Lifting speed is controlled by the speed of the engine and the extent the control lever is pulled. Engine speed has no effect on lowering speed.

Never race the engine while hoisting a load. Too much engine speed will not increase the speed of the hoisting mechanism but may result in fast wear and possible damage to the engine. From practice and experience, you will be able to determine the best hoisting speed by sound, sight, and feel. When a load has been raised to the desired height, ease the hoist lever to the neutral position and move the forklift to the base of the stack the load is to be placed.

Figure 8-22.-Tilt position for picking up round objects.

Although a load maybe placed on or removed from a stack by using the hoist lever, you will learn from practice that a load can be placed or removed entirely with the tilting mechanism. The tilting mechanism is designed to raise the load arms slightly, as the mast is tilted backwards.

Practice raising the load while the forklift draws near the stack to reduce strain on the engine and the brakes. Study the problem of load handling, and keep in mind that carefully planned operations produce the most work with the least fatigue to yourself.

Lift and lower with the mast vertical or tilted slightly back. Tilt elevated loads forward only when they are directly over the unloading place. If the load or lifting mechanism is raised to pick up or deposit a load, reduce the tilt in either direction. Remember the side stability of the load and do not tilt back any farther than is necessary.

CAUTION

Under no condition should additional counterweights be added to any materialshandling equipment to increase its stability or lifting capacity.

Long Objects

As a forklift operator, you may be tasked to move lumber, steel, piling, or pipe. You must know where the center of balance (C/B) is to move long loads. Moving long objects takes special forklift operator skills.

CARRYING.- The load on the forklift shown in figure 8-23 is too wide for the door of the warehouse. In this case, the techniques of operation shown in figure 8-24 should be followed so the forklift and long load can be maneuvered through the door. With practice, this technique can be used to maneuver around most obstacles.

POSITIONING.- The positioning of long objects for loading can be a problem, and it is best to place dunnage under the object if it is not on a pallet. The thickness of the dunnage should allow the forks to slide out freely from the load. To load a piece of pipe, piling, or anything round, you must place blocking or dunnage to prevent the round object from rolling. Then tilt the forks forward until they are flat on the floor and slide them from underneath the object.