Forklift Operator Safety

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Session Objectives
Understand how forklifts work
Operate a forklift safely and skillfully
Identify operating hazards
Apply general principles of safe operation
Properly inspect and maintain a forklift

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 Why Forklift Training
Is Necessary
100 fatalities each year
20,000 lost workday
injuries annually
Common injuries
Hitting a pedestrian
Tipping over
Improperly positioned loads
Falling from raised forks
Falling from a ladder struck
with a forklift
Falling material

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 Forklift Basics Mast

Overhead
Guard Lift
Cylinder

Lift
Control

Lift
Seat Chains
Belt

Tilt
Control Backrest

Carriage

Forks
 Forklift vs. Automobile

Rear of a forklift swings

in opposite direction of
the turn
Forklift impact against
objects magnified
Drives backward and
forward
One hand on controls

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Nameplate
OSHA requires a
legible nameplate
It includes information
about the forklift and
attachments
It lists the maximum
load capacity
It describes the load Image Credit: State of WA-WISHA Services

center

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Determine a Loads
Center of Gravity
Center of gravity is CENTER OF 180LB TOP VIEW OF LIFT TRUCK
the balance point GRAVITY OF LOAD

Load center is the

point where the
heaviest part of the 300LB

load is located CENTER OF GRAVITY

Pick up load on the LOAD CENTER

side closest to its
center of gravity

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Stability Triangle
Vehicle Center of
Gravity (unloaded)
Stability Triangle

Center of Gravity of
Vehicle and Maximum
Load (Theoretical)

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What Can Cause a Tipover?
Center of gravity
side to side
Center of gravity
forward
Center of gravity
backward

Combination of actions or
circumstances can cause tipover
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Attachments
Change operating
clearances
Change capacity
Change stability
and load center

Image Credit: CDC

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Operating Hazards
Pedestrians
Accidents involving
pedestrians may be
caused by:
Obstructed view
Turning
Speeding
Pedestrian unaware
forklift is present
Carrying passengers
and horseplay

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Operating Hazards
Environmental Conditions
Combustible fuel-
operated forklift in
poorly ventilated area
Traveling on ramps
Crossing railroad
tracks
Slippery floors
Operating on dirt
or gravel
Poor lighting

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Operating Hazards
Load Carrying
Working around
loading docks
Loads that block
the forward vision
Stacking and
unstacking on
racks

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Whats Wrong Here?

Forks not fully lowered

Forklift parked on
sloped surface

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Forklift Characteristics and
HazardsAny Questions?
Do you understand:
The characteristics
or basic features of
a forklift
The stability of
forklifts
The hazards specific
to our workplace

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Conduct a
Preoperational Inspection
Conduct a
preoperational
inspection
Follow the inspection
checklist
Complete and sign
the checklist

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Inspection Walkaround

Forklift is properly
disengaged
Walk to both sides
Check front
Walk to rear

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Inspection Walkaround (cont.)
Propane-powered
Check all oil and
fluid levels
Check cables
Check fan belt, fan,
and radiator
Check tank, and
hose attachments
Electric-powered
Check the battery
condition

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While in the Operator Seat
Make nonmoving
checksgauges,
lights, horn, backup
alarm, warning light,
tilt-and-lift mechanism,
and parking brake
Make moving checks
seat belt, running
brakes, and steering
Look for oil or water
leaks on the floor

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Operating a Forklift
Authorized operators
only
Quickly report
accidents
Always wear seat belts
No person under the
forks
Operate controls only
from drivers seat
Never block exits or
emergency equipment

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Tipover Safety Procedure
Always wear your
seat belt
Hold onto the
steering wheel
Brace your feet
Lean away from
the fall

Illustration credit: Rolls High Reach

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Loading and Unloading
Never overload forklift
Check load weight
Locate loads
center of gravity
Inspect the load
Restack or secure
unstable loads
Be sure forks
are under load
Tow from rear
towing pin

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Traveling
Look in the
direction of travel
Keep body inside
cage
Keep forks low
when traveling
Sound the horn
Dont speed
Check clearance

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Traveling (cont.)
Avoid loose objects
or holes
Never carry
passengers
Pedestrians have
the right-of-way
Keep a safe distance
from the edge of ramps
or docks
Never eat or drink
No horseplay

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Ramps and Railroads
No turns on a ramp
Load facing upgrade
Go slow
Cross railroad tracks
diagonally
Never park within
8 feet of the center
of railroad tracks

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Docks
Inspect the dock plate
Check the trailer floor
condition
Make sure trailer
wheels are chocked
Ensure that the nose of
the trailer is supported

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Parking
Dont block exits
or aisles
Lower the forks
Set gear to
neutral
Set the parking
brake
Turn off the key

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Propane Refueling
Fill in well-ventilated
area
Highly flammable
gasdo not smoke
Report leaks
immediately
Distinct odor
Hissing sound
Frost on fittings
Use gloves and safety
glasses

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Battery Charging
Charge batteries only
in protected areas with
ventilation
Inspect battery
connectors for damage
No smoking
Immediately clean up
electrolyte spills
Wear PPE

2008 Schumacher Electric Corp. All rights reserved.

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 Test your Knowledge
1. The first step toward safe WORD BANK
forklift operation is to conduct
preoperational inspection
a _____________
preoperational _________.
inspection
battery test
2. Your inspection should continue
operators seat
operators
when you are in the _________
seat
____. warehouse
authorized drivers
3. Only authorized
__________ drivers
______
should operate a forklift. supervisors
jump
4. If you are in a tipover, never
remain seated
try to jump
____.
low
5. When traveling in a forklift,
high
keep the forks low
___.
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Inspection, Operation, and
MaintenanceQuestions?
Inspection procedures?
Operating procedures?
Vehicle maintenance?

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Key Points to Remember
Facility hazards include pedestrians,
environmental conditions, and
loading/unloading
Position loads close to the vertical backrest
Always conduct and document a
preoperational inspection
Follow the safe operating rules of the road
Always refuel/recharge in ventilated areas
and wear proper PPE
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