© BLR ® —Business & Legal Resources 1202 Alabama Retail is committed to partnering with our members to create and keep safe workplaces. Be sure to check

© BLR®—Business & Legal Resources 1202

Alabama Retail is committed to partnering with our

members to create and keep safe workplaces.

Be sure to check out all of the training tools that are available in our Safety

Library.This training tool is brought to you byThis training tool is brought to you by


Forklift Operator Safety


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


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

Forklift Basics

SeatBelt

LiftControl

OverheadGuard

TiltControl

Forks

Carriage

Backrest

LiftChains

LiftCylinder

Mast

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


Nameplate• OSHA requires a

legible nameplate• It includes information

about the forklift and attachments

• It lists the maximum load capacity

• It describes the load center

Image Credit: State of WA-WISHA ServicesImage Credit: State of WA-WISHA Services


Determine a Load’s Center of Gravity• Center of gravity is

the balance point

• Load center is the point where the heaviest part of the load is located

• Pick up load on the side closest to its center of gravity

LOAD CENTER

CENTER OFGRAVITY OF LOAD

TOP VIEW OF LIFT TRUCK

CENTER OF GRAVITY

180LB

300LB


Stability Triangle

Vehicle Center of Gravity (unloaded)

Center of Gravity of Vehicle and Maximum Load (Theoretical)

Stability Triangle


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


Image Credit: CDC

Attachments• Change operating

clearances

• Change capacity

• Change stability and load center


Operating Hazards— PedestriansAccidents involving pedestrians may be caused by:• Obstructed view• Turning• Speeding• Pedestrian unaware

forklift is present• Carrying passengers

and horseplay


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


• Working around loading docks

• Loads that block the forward vision

• Stacking and unstacking on racks

Operating Hazards—Load Carrying

What’s Wrong Here?

Forklift parked on sloped surface

Forks not fully lowered


Forklift Characteristics and Hazards—Any Questions?Do you understand:

• The characteristics or basic features of a forklift

• The stability of forklifts

• The hazards specific to our workplace


Conduct a Preoperational Inspection• Conduct a

preoperational inspection

• Follow the inspection checklist

• Complete and sign the checklist

Inspection Walkaround

Forklift is properly disengaged

Walk to both sides

Check front

Walk to rear


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


While in the Operator Seat• Make nonmoving

checks—gauges, 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


Operating a Forklift• Authorized operators

only• Quickly report

accidents• Always wear seat belts• No person under the

forks• Operate controls only

from driver’s seat• Never block exits or

emergency equipment


Tipover Safety Procedure• Always wear your

seat belt

• Hold onto thesteering wheel

• Brace your feet

• Lean away fromthe fall

Illustration credit: Rolls High Reach


Loading and Unloading• Never overload forklift

• Check load weight • Locate load’s

center of gravity

• Inspect the load

• Restack or secure unstable loads

• Be sure forks are under load

• Tow from rear towing pin


Traveling• Look in the

direction of travel

• Keep body inside cage

• Keep forks low when traveling

• Sound the horn

• Don’t speed

• Check clearance


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


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


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


Parking• Don’t block exits

or aisles

• Lower the forks

• Set gear to neutral

• Set the parking brake

• Turn off the key


Propane Refueling• Fill in well-ventilated

area

• Highly flammable gas—do not smoke

• Report leaks immediately• Distinct odor• Hissing sound• Frost on fittings

• Use gloves and safety glasses


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.

Test your Knowledge1. The first step toward safe

forklift operation is to conduct a _____________ _________.

2. Your inspection should continue when you are in the _________ ____.

3. Only __________ ______ should operate a forklift.

4. If you are in a tipover, never try to ____.

5. When traveling in a forklift, keep the forks ___.

WORD BANK


battery test

operator’s seat

warehouse

authorized drivers

supervisors

jump

remain seated

low

high


operator’sseat

authorized drivers

jump

low


Inspection, Operation, and Maintenance—Questions?• Inspection procedures?

• Operating procedures?

• Vehicle maintenance?


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

Documents

© BLR ® —Business & Legal Resources 1202 Alabama Retail is committed to partnering with our members to create and keep safe workplaces. Be sure to check