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© BLR®—Business & Legal Resources 1202
Forklift Operator Safety
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
Stability Triangle
Vehicle Center of Gravity (unloaded)
Center of Gravity of Vehicle and Maximum Load (Theoretical)
Stability Triangle
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
Image Credit: CDC
Attachments• Change operating
clearances
• Change capacity
• Change stability and load center
© BLR®—Business & Legal Resources 1202
Operating Hazards— PedestriansAccidents involving pedestrians may be caused by:• Obstructed view• Turning• Speeding• Pedestrian unaware
forklift is present• Carrying passengers
and horseplay
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
• 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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
Tipover Safety Procedure• Always wear your
seat belt
• Hold onto thesteering wheel
• Brace your feet
• Lean away fromthe fall
Illustration credit: Rolls High Reach
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
Traveling• Look in the
direction of travel
• Keep body inside cage
• Keep forks low when traveling
• Sound the horn
• Don’t speed
• Check clearance
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
Parking• Don’t block exits
or aisles
• Lower the forks
• Set gear to neutral
• Set the parking brake
• Turn off the key
© BLR®—Business & Legal Resources 1202
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
© BLR®—Business & Legal Resources 1202
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
preoperational inspection
battery test
operator’s seat
warehouse
authorized drivers
supervisors
jump
remain seated
low
high
preoperational inspection
operator’sseat
authorized drivers
jump
low
© BLR®—Business & Legal Resources 1202
Inspection, Operation, and Maintenance—Questions?• Inspection procedures?
• Operating procedures?
• Vehicle maintenance?
© BLR®—Business & Legal Resources 1202
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