Material Stacker Operator Training-Student

Material Stacker Operator Training
Course Outline
We will share with you:
1. Daily Operator Instructions;
2. Periodic Inspection Requirements;
3. Operational Safety;
4. Load Planning
Why this Training?
Fatalities or serious injuries can occur if manually operated or powered
load handling equipments are not inspected and properly used. Fatalities
may occur when workers doesn’t pay attention to their work.
In the US, 1021 workers died from traumatic injuries suffered in powered
load handling equipments related incidents from 1997 to 2010.
Why we need Handling Equipment?
Definition
Powered Load Handling Equipment, commonly called

forklifts or material stacker or lift trucks, are used in many
industries, primarily to move materials. They can be used
to move, raise, lower, or remove large objects or a
number of smaller objects on pallets or in boxes, crates,
or other containers.
Why we need handling equipment?
Manual handling is an activity that takes place in most

workplaces. Often, manual handling is a routine part of
day-to-day work activity. All the manual handling activities
generate the possibility of injuries, most of which are
musculoskeletal injuries.
Back injury
Tendons and ligaments injuries
Muscle injuries
Work related upper limb disorders
Cuts, burns, dislocation and broken bones; etc.
Types and Fundamentals
This module reviews the classes of commonly-used powered
industrial trucks. It also summarizes the major types of
power sources used in powered industrial trucks and
reviews safe practices for refueling and battery
charging/changing operations. Finally, this module reviews
the major parts of a powered industrial truck, including some
of the potential hazards and possible solutions associated
with each part.
 Types;
 Power Sources; &
 Parts.
Types
The following are classes of commonly-used
powered industrial trucks.
Class I: Electric Motor Rider Trucks
Class II: Electric Motor Narrow Aisle Trucks
Class III: Electric Motor Hand Trucks or Hand/Rider Trucks

Types - Continued
Class IV: Internal Combustion Engine Trucks (Solid/Cushion Tires)
Class V: Internal Combustion Engine Trucks (Pneumatic Tires)
Class VI: Electric & Internal Combustion Engine Tractors
Class VII: Rough Terrain Forklift Trucks
Electric – Power Source
Electric-powered equipments are most commonly used

indoors in warehouses. Unlike internal combustion forklifts,
electric forklifts are quiet and generally non-polluting. Electric
stacker produce zero emissions, virtually eliminate the
hazard of carbon monoxide poisoning, and run more quietly
Than internal combustion equipments.
Name Plate
Each operator is required to be
aware of the truck specifications on
the nameplate and what they
mean. If there is a special
attachment, it must be listed on the
nameplate.
This data label indicates that this forklift has a 156" upright
mast height in column A and a 24" load center in column B. Its
stated capacity is 5,000 lbs with just its forks. With the
sideshifter attachment, its stated capacity is 4,500 pounds.
The truck weighs 8,600 pounds.
Capacity
The capacity is the manufacturer’s guideline for how much
weight an equipment can safety lift. Exceeding the capacity
of an equipment presents serious hazards, including tipover.
If the load has a different load center or it is irregular, such

as a series of boxes of varying weights, then the capacity
must be recalculated.
Warning & Safety Devices
Powered industrial trucks may be equipped by the
manufacturer with the following safety devices:
Seat belts and similar restraints
Horns
Backup alarms that sound when equipment reverses
Fire extinguisher
Warning lights that flash
Directional signals and brake lights
Mirrors
Operator Certification
Schlumberger
Only certified operators are allowed to operate.

Operator Information
Age
Health
Professional Training
Responsibilities
Age / Health
Age: The operator should not be less than 18 years old.
Health: Health is important for operating the equipment and you

should avoid operating an equipment if you are under medical
treatment and taking drugs that make you feel dizzy, sleepy,
numbed...
Particular attention should be paid to vision ability and hearing.

Equipment Safety and Operator Inspections
Personal Safety Equipment
 Hard hat
 Coveralls
 Gloves
 Safety shoes / boots
 Safety glasses
Pre Operation Checks
It is required by law that all powered equipments be
examined at least daily before being placed in service.
Equipments used on a round-the-clock basis must be
examined after each shift.
The operator should conduct a pre-start visual check with

the key off and then perform an operational check with the
engine running. The equipment should not be placed in
service if the examinations show that the equipment may not
be safe to operate.
Before starting your vehicle, conduct a pre-operation (or pre-start) inspection that
checks a variety of items, including but not limited to:
 Fluid levels -- oil, water, and hydraulic fluid.
 Leaks, cracks or any other visible defect including hydraulic hoses and mast
chains. NOTE: Operators should not place their hands inside the mast. Use a
stick or other device to check chain tension.
 Tire condition and pressure including cuts and gouges.
 Battery Condition
 Condition of the forks, including the top clip retaining pin and heel.
 Load backrest extension.
 Safety decals and nameplates. Ensure all warning decals and plates are in
place and legible. Check that information on the nameplate matches the model
and serial numbers and attachments.
 Operator manual on truck and legible.
 Operator compartment. Check for grease and debris.
 All safety devices are working properly including the seat belt.
Operational Checks
After completing the pre-operation inspection, operators should conduct an
operational inspection with the engine running. This inspection includes:
 Accelerator linkage
 Brakes
 Steering
 Drive control: forward and reverse
 Tilt control: forward and back
 Hoist and lowering control
 Attachment control
 Horn
 Lights
 Back-up alarm (if equipped)
 Hour meter
Battery Charging (Battery Operated)
• Park near the Charging Unit
• Apply Parking Brakes
• Turn off / Remove keys
• Connect charging unit cable
• Turn On the Charging Unit
• Make sure charging is started
Operating at Speed
Potential Hazards:
 Tipover caused by driving too fast.
 Collision with pedestrians and obstacles caused by inattention and not being
able to stop in time.
Premises & Maneuvering Areas
It is essential that the
 Areas designed for the charging of batteries offer all guarantees of safety
 Floors have the necessary strength and don’t present defects detrimental to the
proper use of equipment.
 Travelling lanes are clearly market and free of obstructions, with a well designed
layout and of sufficient width, and when necessary with adequate traffic signs.
 Pedestrian circulation is well segregated from forklift traffic. Separate doors, floor
marking, traffic lights etc are provided.
RADIUS
The radius is the distance between the fork back to the gravity centre of the load.
Loading Capacity & COG
The load that the forklift can handle decrease when the radius increase.
Loading Capacity & COG
The same load handle with different radius can be very dangerous. Always check the load and
radius on the load plate before to perform a lifting operation.
LOAD CHART
Loading Plate
 The further the load is from the fork heel the greater the reduction in lifting capacity
Loading Plate
 The greater the height and incline the greater the reduction in lifting
capacity of the truck
Loading Rules
• Never exceed the maximal load

Loading Rules
X Schlumberger
 Never exceed the counterbalance value

Loading Rules
 Set the forks in the lowest

and widest position, then
balance and fasten load
Loading Rules
 Load perfectly balanced

Driving Rules
General rules for driving

 Always wear your seat belt
 Consider available height
 Consider load size
 Never drive with feet or body outside the roll bar
 Drive up & down slowly
 Turn off engine during a long parking
 Respect the highway code when driving on open traffic way (if
allowed)
 Never drive with the load high
 Drive with forks at 6” (15cm) off the ground
Driving Rules
General rules for driving

 Drive down slopes backwards
 Binding and lifting down loads using tilted mast
 Driving empty with forks 6” (15cm) off the ground and back rest
tilted back
Power Lines
 Compare the raised upright height to the power line height - if
capable of touching the line AVOID working in the area
Driving Upward-Downward on Slope
• When loaded, travel down or up slopes with the fork arms
facing uphill.
•
•Travel slowly when descending slopes as shown.
Driving Upward-Downward on Slope
• When unloaded, travel up or down slopes with fork arms

facing downhill.
• It may be necessary to raise the fork arms slightly at the
bottom of slopes to avoid grounding the load or fork arms
• Travel slowly when descending slopes.
Safety Rules
Never allow anybody to walk under a

raised load (including empty forks)
Schlumberger
Safety Rules
Only an approved platform may be used to

lift another person
Schlumberger
Rules for Loading
The following rules must be strictly adhered to never exceed the safe working load (SWL) of the
equipment and strictly follow the indications of the plate affixed to the machine.
Ender no circumstances may the counterweight be increased by adding weights or standing other
personnel on the back in order to lift loads higher than those specified by the manufacturer.
Before any lifting, ensure that platforms, pallets, box pallets etc. are adapted to the loads to be lifted
and in adequate condition.
Ensure that the loads are perfectly balanced, wedged or fastened to their supports in order to
prevent any risk of sliding or tilting.
Engage the forks fully underneath the loads, raise slightly and immediately tilt the back.
GENERAL RULES FOR DRIVING AND TRAVELLING
 Look in the direction of travel and always maintain a clear visibility of the area.
 Travel at reasonable speed. Also follow site specific speed limits.
 Slow down at dangerous points and when pedestrians are in the vicinity.
 Avoid sudden starts, turns and stops.
 Approach bends at reduced speed. overturning at bends is a major cause of fatal accidents occurring With
trucks.
General Rules
 Keep an eye on the load, particularly at bends, and if it is very bulky or unstable.
 iI visibility in forward motion is insufficient due to the size of the load, travel in reverse. this practice however
must be kept minimum and for short distances; if not, use better adapted handling equipment or reduce the
height of the load.
 Use the horn with moderation.
 On wet, slippery or uneven ground, drive slowly.
 Brake progressively and smoothly.

General Rules
 Be aware of maximum height at doors.
 When reaching a two-way door, stop, use the

horn and watch if the passage is free and slowly
push the doors with the equipment.
 Be prepared to carry out any unforeseen

maneuvers.
 Take a safe and correct position on the truck.
 Maintain sufficient distance between two trucks

travelling in the same direction.
 Vever drive with wet or greasy hands or shoes.

General Rules
 Never travel with the load in the

raised position, but always with the
load in low positions about 15 cm from
the ground and tilted back to the
maximum.
 When travelling without load, keep

the fork about 15 cm above ground.
Stopping the Equipment
Do not stop the equipment in a location where it could impede other traffic, or on a slope unless
absolutely necessary. in this case make sure that the wheels are adequately chocked.
Do not forget that it is expressly forbidden to walk underneath a fork in the elevated position, even
without load.
Parking
When Parking the lift truck, even for a few seconds
 Move to the designated parking place
 Apply the parking brake
 Make sure the controls are in neutral
 The fork arms are empty
 The fork arms are tilted forward and lowered to the ground
 Shut off the power and remove the key or other activating device
LEAVING THE FORKLIFT
When leaving the equipment ensure that:
The engine / motor is stopped.
The parking brake is on.
The ignition key or equivalent has been removed.
Ensure that the fork is resting flat on the ground, or it not possible that it is
Raised at least 2m from the ground.
At the end of the work period, park the truck in the designated place. protect it against potential weather
damage, (rain heat etc.)
DRIVING RULES
GANGWAYS
Never drive onto a gangway without being absolutely sure

that it has been designed for the weight and size of the
loaded truck, and that it is in good working order.
TRANSPORTING AND LIFTING PEOPLE
Transporting and lifting persons with trucks is expressly

forbidden.
Stacking
 Approach the stack with the load low, reached in and tilted slightly backwards
 Slow down and stop at the face of the stack
 Apply the parking brake
 Select neutral if applicable, and reduce the backward tilt to an amount just
sufficient to maintain the load stability
 Look up and check for obstructions,
 Raise the load to the desired stacking height
Stacking
 Move forward if necessary, to bring the reach truck close to the stack
 Reapply the parking brake, selecting neutral if applicable.
 Reach out smoothly, taking care not to dislodge loads in adjacent stacks
 When the load is squarely over the stack, level the load and lower it onto the
stack gently and smoothly
 When the load is securely stacked, lower the fork arms until free of the pallet
 The stacker should be moved back a short distance, after ensuring the way is
clear
Stacking
• When the fork arms are clear of the stack
• Reapply the parking brake if the stacker has been moved
• Lower the fork arms to just above ground level, apply a slight backtilt
• Check the way is clear before moving off
De-stacking
• Halt at the face of the stack and apply the parking brake, selecting
neutral if applicable.
• Bring the mast to the vertical position
• If necessary, adjust the fork arm spread to suit the width of the load
• Ensure that the weight of the load is within the capacity of the stacker
• Look up and check for obstructions
• Raise the fork arms to a position permitting clear entry into the pallet
De-stacking
• Move forward if necessary, to bring the reach truck close to the stack and
re-apply the parking brake.
• Fully insert the fork arms by reaching out until the heels of the forks gently
touch the load or pallet base
• Lift the load until it is clear of the stack and carefully apply a backward tilt just
sufficient to stabilize the load
De-stacking
• Move the reach truck slightly backwards away from the stack,
ensuring that the way is clear and taking care not to dislodge loads in
adjacent stacks.
• Re-apply the parking brake if the stacker has been moved
• Lower the load carefully and smoothly to the correct travelling position
• Apply the requisite backtilt before checking the way is clear and moving off
ANY QUESTION ?
THANKS

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What are the different classes of powered industrial trucks?

What are the different classes of powered industrial trucks?

What are some of the potential hazards associated with different parts of powered industrial trucks?

What are some of the potential hazards associated with different parts of powered industrial trucks?

Material Stacker Operator Training

We will share with you:

1. Daily Operator Instructions;

2. Periodic Inspection Requirements;

Powered Load Handling Equipment, commonly called

Manual handling is an activity that takes place in most

Class I: Electric Motor Rider Trucks

Class II: Electric Motor Narrow Aisle Trucks

Class III: Electric Motor Hand Trucks or Hand/Rider Trucks

Electric-powered equipments are most commonly used

If the load has a different load center or it is irregular, such

Only certified operators are allowed to operate.

Health: Health is important for operating the equipment and you

Particular attention should be paid to vision ability and hearing.

 Safety shoes / boots

The operator should conduct a pre-start visual check with

• Never exceed the maximal load

 Never exceed the counterbalance value

 Set the forks in the lowest

 Load perfectly balanced

General rules for driving

General rules for driving

• When unloaded, travel up or down slopes with fork arms

Never allow anybody to walk under a

Only an approved platform may be used to

 Travel at reasonable speed. Also follow site specific speed limits.

 Avoid sudden starts, turns and stops.

 Use the horn with moderation.

 On wet, slippery or uneven ground, drive slowly.

 Brake progressively and smoothly.

 Be aware of maximum height at doors.

 When reaching a two-way door, stop, use the

 Be prepared to carry out any unforeseen

 Take a safe and correct position on the truck.

 Maintain sufficient distance between two trucks

 Vever drive with wet or greasy hands or shoes.

 Never travel with the load in the

 When travelling without load, keep

When leaving the equipment ensure that:

The engine / motor is stopped.

The parking brake is on.

The ignition key or equivalent has been removed.

Raised at least 2m from the ground.

Never drive onto a gangway without being absolutely sure

TRANSPORTING AND LIFTING PEOPLE

Transporting and lifting persons with trucks is expressly

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