Forklift Safety

FORKLIFT SAFETY
(1999 REVISION)
OSHA TRAINING
ACME
PARTS CLARK
OSHA 29CFR 1910.178

COURSE OBJECTIVES
 Introduce Training and Regulatory Requirements.
 Discuss Basic Forklift Operating Principles.
 Discuss Forklift Safety Requirements.
 Discuss the Different Types of Forklifts.
 Discuss Hazardous Driving Situations.
 Conduct a Written and Driving Proficiency Test.
STUDENT LEARNING OUTCOMES
 Understand Safety Regulations Regarding Forklifts.

 Understand Basic Forklift Operating Principles.
 Understand the Hazards Involved With Forklifts.
 Successfully Operate Forklifts Safely.
 Successfully Complete a Written Proficiency Test.
 Successfully Complete a Driving Proficiency Test.
ANSI STANDARD
POWERED INDUSTRIAL TRUCKS
ANSI
American National Standard
for
Powered Industrial Trucks
Part II, B56.1-1969
REGULATORY STANDARD
POWERED INDUSTRIAL TRUCKS
29CFR - 1910 - 178
29CFR - Safety and Health Standards
1910 - General Industry
178 - Powered Industrial Trucks

FORKLIFT INJURY STATISTICS
APPROXIMATELY 34,000 RELATED INJURIES A YEAR:
 INATTENTION
 DISTRACTION
 EXCESSIVE SPEED
 POOR DRIVING HABITS
 LACK OF TRAINING
CIRCUMSTANCES OF INJURY
HOW MOST INJURIES OCCUR
 Overloading Causing the Vehicle to Turnover.

 Load Instability Causing Turnover.
 Obstructions in the Path of Travel or Lift.
 Using Forklift Outside of Design Limitations.
 Striking a Pedestrian.
CASE STUDY #1
CRUSHED AGAINST A STEEL POLE
NARRATIVE: AN EMPLOYEE WAS SPOTTING A FORKLIFT

BACKING UP IN A CONGESTED FLOOR AREA. THE
OPERATOR ATTEMPTED TO EASE THE VEHICLE SLOWLY
BACK TO GAIN CLEARANCE TO TURN. THE GAS PEDAL
STUCK SLIGHTLY CAUSING THE VEHICLE TO LURCH,
PINNING AND CRUSHING THE SPOTTER BETWEEN THE
FORKLIFT AND A POLE RESULTING IN FATAL INJURIES.
CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN A
FIXED OBJECT AND THE VEHICLE.
CASE STUDY #2
KILLED BY TOPPLED FORKLIFT
NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL

FROM A LOADING DOCK TRAILER TO A WAREHOUSE
LOCATION WHEN THE VEHICLE WAS DRIVEN OFF OF THE SIDE
OF THE DOCK RESULTING IN A LATERAL TIPOVER OF THE
VEHICLE AND FATAL OPERATOR INJURIES.
CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE

EDGE OF THE DOCK AND THE VEHICLE.
CASE STUDY #3
KILLED BY TOPPLED FORKLIFT
NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL

FROM A STACKED PALLET STORAGE LOCATION TO THE
WAREHOUSE FLOOR. THE OPERATOR BEGAN MOVING THE
VEHICLE WITH THE LOAD EXTENDED BEFORE LOWERING
THE LOAD, RESULTING IN A CENTRIFUGAL OVERLOAD AND
TOPPLING. THE OPERATOR WAS CRUSHED BY THE
VEHICLE.
CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL

TRAINING REQUIREMENTS
(1999 REVISION)
HOW THIS COURSE IS STRUCTURED:

 Classroom Lecture.
 Supporting Audio/Video Aids.
 Student Discussion/Interaction.
 Field Discussion of Specific Vehicles.
 Field Evaluation of Your Performance.
(1999 REVISION)
MEASUREMENT OF OPERATORS PERFORMANCE:

 You Will Be Given Training Specific to the Vehicle.
 Your Performance Will Be Observed.
 You Must Pass an Operating Performance Test.
 You Must Pass a Written Performance Test.
TRAINEE REQUIREMENTS
(1999 REVISION)
TRAINEES MAY OPERATE A FORKLIFT ONLY:
1. Under the Direct Supervision of Persons Who Have the

Knowledge, Training, and Experience to Train Operators
and Evaluate Their Competence; And
2. Where Such Operation Does Not Endanger the Trainee or

Other Employees.
TRAINEE REQUIREMENTS
(1999 REVISION)
TRAINEES MUST BE PROPERLY TRAINED:

1. Training Must Consist of a Combination of Formal Instruction
(Lecture, Discussion, Video Tape, Written Material).
2. Practical Training
(Demonstrations Performed by the Trainer)
3. Practical Exercises
(Exercises Performed by the Trainee)
4. Evaluation of the Operator's Performance in the Workplace.

(1999 REVISION)
TRUCK TOPICS TO BE ADDRESSED:

 Operating Instructions.
 Warnings, and Precautions.
 Differences Between the Truck and the Automobile.
 Truck Controls and Instrumentation.
 Engine or Motor Operation.
 Steering and Maneuvering.
 Visibility (Including Restrictions Due to Loading.
(1999 REVISION)
TRUCK TOPICS TO BE ADDRESSED:

 Fork and Attachment Adaptation.
 Fork and Attachment Operation, and Use Limitations.
 Vehicle Capacity.
 Vehicle Stability.
 Operator Vehicle Inspection and Maintenance.
 Refueling of the Vehicle.
 Charging and Recharging of Batteries.
 Vehicle Operating Limitations.
 Surface Operating Conditions.
(1999 REVISION)
WORKPLACE-RELATED TOPICS TO BE ADDRESSED:

 Composition of Loads to Be Carried
 Load Manipulation, Stacking, and Unstacking.
 Pedestrian Traffic in Operating Areas.
 Restricted Spaces and Operating Locations.
 Hazardous (Classified) Operating Locations.
 Ramps and Other Sloped Surfaces.
 Closed Environments Poorly Ventilated Areas.
 Unique or Potentially Hazardous Operating Areas.
 The Requirements of the Standard.
RETRAINING REQUIREMENTS
(1999 REVISION)
RETRAINING IS REQUIRED WHEN:

 An Unsafe Operation of a Forklift Is Observed.
 An Accident or Near-Miss Incident Occurs.
 An Operator Receives an Unfavorable Driving Report.
 An Operator Is Assigned to a Different Type of Truck.
 A Change in Attachment/Handling Equipment Occurs.
 Workplace Conditions Changes that Affect Safety.
 A Failure Occurs in Written Safety Procedures.
 There Is Reason to Doubt Employee Proficiency.
 Every Three Years.
FORKLIFT SAFETY PROGRAM
ELEMENTS OF THE PROGRAM:
1. Written Company Safety Procedures.

2. Employee Training.
3. Measurement of Training Effectiveness.
4. Measurement of Driving Proficiency.
FORKLIFT SAFETY PROGRAM
WRITTEN COMPANY SAFETY PROCEDURES:
1. Company Forklift Policy Reviewed Annually.

2. Daily Operator Inspections Documented.
3. Driving Training and Proficiency Documented.
FORKLIFT TRAFFIC PATTERNS
SETTING UP THE PATTERN:
 Aisles Must Be Well-Lighted and Obstruction Free.

 Aisles Must Be Clearly Marked and of Ample Width.
 Driving Surfaces Must in Good Repair.
 Pedestrians Must Be Accounted for in the Pattern.
 Regulatory Signs Must Be Prominent and Enforced.
 Guardrails, Door Warnings, Mirrors and Other.
 Standard Precautions Must Be Considered and Installed.
FORKLIFT TRAFFIC PATTERNS
DEPT - A DEPT - B DEPT - C DEPT - D OFFICE
DEPT - E DEPT - F DEPT - G DEPT - H
= FORKLIFT ROUTE
FORKLIFT TYPES AND DESIGNATIONS
VARIOUS TYPES OF FORKLIFT CONFIGURATIONS:
D Diesel
DS Diesel- With Additional Safeguards to Exhaust, Fuel Etc.
DY Diesel- Like Ds but Having No Electrical Equipment
E Electrically Powered
ES Like E but With Additional Spark Precautions Installed
EX Like E but With Additional Vapor Precautions Installed
G Gasoline
GS Gasoline but With Additional Safeguards to Exhaust
LP Propane
FORKLIFT TYPES AND DESIGNATIONS
NOTE: YOU MUST ENSURE THAT THE TYPE OF

FORKLIFT YOU ARE USING IS COMPATIBLE WITH
THE TYPE OF ENVIRONMENTS AND WORKING
CONDITIONS THE VEHICLE WILL BE EXPOSED TO.
BASIC FORKLIFT PRINCIPLES
FORKLIFT MANUFACTURER:
 Dictates Specific Operation of Vehicle.
 Maintains Operation and Maintenance Manuals.
 Specifies Maintenance Requirements.
 Consulted Concerning “Attachment’s”.
 First Choice for Safety Questions.
 OVERHEAD GUARD
 MAST
 CARRIAGE
 BACKREST
LOAD CAPACITY
6000 lbs
 LIFT CYLINDER
PROPANE ONLY
 TILT CYLINDERS
 FORKS
TYPES OF FORKS
 HALF-TAPERED FORKS
- USED WITH HEAVIER LOADS
 FULL-TAPERED FORKS
- USED WITH LIGHTER LOADS
- USED WITH NARROW PALLETS
TYPES OF TIRES
 PNEUMATIC AIR FILLED TIRES AIR
- USED WITH HEAVIER LOADS

- OUTDOORS OR UNEVEN SURFACES
SOLID RUBBER
 PNEUMATIC SOLID TIRES
- PUNCTURE PROOF
- INTERCHANGED WITH AIR FILLED
CONSULT YOUR VEHICLE OWNERS MANUAL

TYPES OF TIRES
CUSHION
 CUSHION TIRES
- INDOORS OR SMOOTH SURFACES
SOLID RUBBER
 SOLID TIRES
- PUNCTURE PROOF
- SMOOTH INDOOR SURFACES

AUTO STEERING VERSES FORKLIFT STEERING:
TRAVEL TRAVEL
AUTO FORKLIFT
TURNING PRINCIPLE
PIVOT POINT WITH AN AUTOMOBILE
THERE IS NO “SWING OUT”,
IN OTHER WORDS, THE
VEHICLE FOLLOWS THE
TURNING RADIUS OF THE
FRONT WHEELS.
TRAVEL
AUTO
PIVOT POINT
TURNING PRINCIPLE
WITH A FORKLIFT, THERE IS
CONSIDERABLE “SWING
TRAVEL OUT”, IN OTHER WORDS,
THE VEHICLE FOLLOWS
THE TURNING RADIUS OF
THE REAR WHEELS.
SWING RADIUS
DANGER ZONE FORKLIFT

THE RATED CAPACITY

 The Maximum Amount of Weight That Can Be Safely Lifted.
 How the Load Rests on the Forks Is Critical.
 The Closer the Load Is to the Backrest the Better.
 Can Be Found on the Nomenclature Plate of the Vehicle.
OPERATING NEAR PEDESTRIANS

 Three mph Speed Limit Near Pedestrians.
 Establish Eye Contact When Possible.
 Acknowledge Their Presence With A Nod.
 Avoid Congested Pedestrian Areas If Possible.
 Panic Stop Distances For Typical Loaded Truck.
- 01 mph = 1 - 3 Feet
- 10 mph = 22 Feet
- 18 mph = 55 Feet
LIFTING PRINCIPLE
COUNTER PIVOT POINT PIVOT POINT COUNTER WEIGHT

WEIGHT
LIFTING PRINCIPLE
MOVING THE LOAD AWAY FROM

REAL HEAVY PARTS
THE BACKREST CAN LOWER
THE RATED CAPACITY OF THE
6500lbs
FORKLIFT BY HUNDREDS OF
POUNDS!
INCORRECT

LIFTING PRINCIPLE
REAL HEAVY PARTS REAL HEAVY PARTS
6500lbs 6500lbs
INCORRECT CORRECT

CENTRIFUGAL FORCES
REAL HEAVY PARTS
MOVING OR TURNING THE VEHICLE

6500lbs
WHEN THE LOAD IS EXTENDED CAN
RESULT IN TURNOVER BECAUSE OF
CENTRIFUGAL FORCES APPLIED AT
THE TOP OF THE LOAD!
FORK ADJUSTMENT
FORKS SHOULD BE SPREAD AS

WIDE AS POSSIBLE TO ALLOW FOR
MAXIMUM STABILITY OF THE LOAD!
FORKLIFT OPERATING PRINCIPLES
PRE-USE INSPECTION
 Mast  Cylinder Mounting Hardware
 Roller Tracks and Chains  Tires
 Forks and Adjustment  Lights and Warning Devices
 Fluid Levels  Handbrake
 Hydraulic Lines  Steering and Brakes
 Lift and Tilt Cylinders  Driving Controls
 Overhead Guard Mounting  Lift Controls
 Fire Extinguisher  Seat Adjustment and Belts
TYPES OF POWER SOURCES
 BATTERY POWERED
 PROPANE POWERED
 DIESEL POWERED
 GASOLINE POWERED

INSPECTION OF POWER SOURCES
 BATTERY POWERED
- REQUIRES CONSTANT CHARGING
- NO IGNITION SOURCES IN CHARGING AREA
- FOLLOW LOCAL CHARGING PROCEDURES

BATTERY SAFETY PRECAUTIONS

1. Mechanical Lifting Aids Required for Battery Handling.
2. Charging Area Must Have Working Eyewash Station.
3. Wear Complete Splash Protection When Servicing Batteries.
4. Battery Charging Is Only Allowed in Predesignated Areas.
5. Ventilation Must Be Adequate to Disperse Hydrogen.
6. Ventilation Must Be Adequate to Disperse Corrosive Gases.
7. Open Flames May Not Be Used to Check Electrolyte Levels.

BATTERY SAFETY PRECAUTIONS

8. Battery Cover Must Be Left Open During Charging.
9. Ventilation Ensures Clean Air and Heat Dissipation.
10. Always Disconnect Charging Connector Properly.
11. Only Pull on Charging Connector in an Emergency.
12. Properly Reposition Battery After Removal.
13. Improperly Positioned Batteries May Shift.
14. Use Wooden (or Approved) Spacers As Necessary.

BATTERY FILLING PRECAUTIONS
OK! BATTERY
HANDLING BULK ELECTROLYTE

1. Bulk Containers Must Be Moved Using Carboy or Tilter.
2. Siphons Are Acceptable. Never Start Siphon By Mouth.
3. Never Smoke Around Electrolyte.
4. Eliminate Sparks or Other Ignition Source In Charging Area.
5. Use Only Non Sparking, Non Conductive Tools.
6. Apply Vehicle Emergency Brake When Charging.
7. Inspect Vent Caps On Battery. Ensure They Are Free.

ELECTROLYTE MIXING PRECAUTIONS
NO! ACID
CORROSIVE
ELECTROLYTE MIXING PRECAUTIONS
YES! WATER
 PROPANE POWER
- INSPECT TANK FOR SERVICEABILITY
- INSPECT PROPANE TRANSFER SYSTEM
- INSPECT TANK RESTRAINT SYSTEM
- FOLLOW LOCAL REPLACEMENT PROCEDURES

PROPANE SAFETY PRECAUTIONS

1. Extinguish Smoking Materials.
2. Ensure No Ignition Sources Are Present.
3. Wear Protective Gloves and Eye Protection.
4. Ensure Valve Is Closed Anytime the Tank Is Disconnected.
5. Follow Manufacturers Instructions for Refueling the Vehicle.
6. After Tank Is Removed From the Vehicle, Inspect for Damage.
7. If Tank Is Serviceable, Have It Moved to Empty Tank Storage.
8. If You Have Any Safety Concerns Contact Safety.

PROPANE CONNECTION CONSIDERATIONS

1. Inspection Tank for Defects and Dents.
2. Never Throw, Drag, Drop, or Roll LPG Containers.
3. Check Fuel Lines for Serviceability.
4. Check for Damage to Liquid Level Gauge.
5. Inspect Quick-Disconnect Couplings for Serviceability.
6. Inspect Threads, Valves and Fittings for Serviceability.
7. Check to Ensure Relief Valve Is Pointed in Specified Direction.

A NOTE ABOUT THE LPG TANK ACCESS VALVE
Never Jam the Valve in the Open Position (When

Opening the Valve). Open Fully, Then Turn Toward
The Closed Position 1/4 to 1/2 Turn. This Action
Prevents Jamming and Enables Quick Shut off in
an Emergency. Close the Valve When the Truck
Will Be Parked for Extended Periods of Time.

 DIESEL AND GASOLINE POWERED

- INSPECT FOR LEAKS
- ENSURE ADEQUATE VENTILATION EXISTS
- FOLLOW LOCAL REFUELING PROCEDURES

DIESEL AND GASOLINE SAFETY PRECAUTIONS

1. Extinguish Smoking Materials.
2. Ensure No Ignition Sources Are Present.
3. Wear Protective Gloves and Eye Protection.
4. Ensure Area Is Approved for Refueling.
5. Follow Manufacturers Instructions for Refueling the Vehicle.
6. Ensure Area Has Ample Ventilation.
7. Ensure Tank Is Not Over Filled Causing Spillage.
8. Do Not Start Vehicle Until All Spilled Fuel Is Eliminated.

STARTING THE FORKLIFT
 Apply the Foot Brake.

 Shift Gears to Neutral.
 Ensure Load Is Lowered and Controls Neutralized.
 Start Forklift and Check Gauges.
 Disengage Hand Brake.
 Check Controls, Steering and Brakes.

SHUTTING DOWN THE FORKLIFT

 Apply the Hand Brake.
 Lower the Load.
 Turn off the Engine.
 Neutralize the Controls (Dissipate Line Pressures).
 Follow Procedures for Propane.
 Follow Procedures for Battery Powered Vehicles.

DEFINITION - ATTENDED VEHICLE

IF OPERATOR IS DISMOUNTED:
 Operator Is Within 25 Feet of the Vehicle.
 Operator Has Line-of-Site of the Vehicle.
 Operator Has No Obstruction of Access to Vehicle.
 Load Engaging Means Is Fully Lowered.
 Controls Neutralized and Handbrakes Set.

DEFINITION - UNATTENDED VEHICLE

IF OPERATOR IS DISMOUNTED:
 Operator Is More Than 25 Feet From the Vehicle.
 Operator Has No Line of Site of the Vehicle.
 Operator Is Obstructed From Access to Vehicle.
 Load Engaging Means Is Not Fully Lowered.
 Handbrakes Not Set.

HANDLING AND MOVING LOADS
VISIBILITY DURING FORKLIFT OPERATIONS
 Approach the Load Slowly and Do Not “Bump”.

 Know Where All Bystanders Are Located.
REAL HEAVY PARTS
ACME
FORKLIFTS
TRAVEL
6500lbs
VISIBILITY DURING FORKLIFT OPERATIONS

 Never Allow Bystanders Between You And a Fixed Object.
 Know Where All Spotters Are Located.
 If You Lose Sight of a Spotter, Stop and Relocate Them.
 ASSUME LOST SPOTTERS ARE IN YOUR PATH.
ACME
FORKLIFTS
TO PICK UP A LOAD
 Approach the Load Slowly and Straight on (Load Centered).
 Stop When the Tip of the Forks Are About a Foot Away.
 Level Forks and Adjust Fork Height.
 Move Forward Slowly Until Load Is Fully Against Backrest.
 Lift the Load High Enough to Clear Floor Obstructions.
 Back the Load Out Slightly From the Storage Location.
 Carefully Tilt Mask Back to Stabilize the Load.
 Ensure Rear Is Clear, Back Out.
TO PUT DOWN A LOAD

 Approach the Delivery Location Straight On.
 Stop When the Tip of the Forks Are About a Foot Away.
 Lower Load, Carefully Level Forks.
 Move Forward Slowly Until Load Is in Desired Location.
 Lower the Load to Floor or Storage Location.
 Ensure Forks Are Clear of Pallet.
UNSTACKING LOADS
 Approach the Load Slowly and Straight on (Load Centered).
 Stop About a Foot Away and Raise Forks to Desired Height.
 Level Forks and Drive Forward.
 Move Forward Slowly Until Load Is Fully Against Backrest.
 Lift the Load High Enough to Clear Obstructions.
 Once the Stack Is Cleared - Lower to Desired Height.
 Carefully Tilt Mask Back to Stabilize the Load.
STACKING LOADS
 Approach the Location Slowly and Straight On.
 Stop About a Foot Away and Raise Load to Desired Height.
 Drive Forward Until Load Is Square Over Stack.
 Level Forks and Lower Load Until Load Is Supported.
 Ensure Forks Are Clear of Pallet.
DRIVING WITH A LOAD

 Travel With the Load Tilted Slightly Back for Stability.
 If You Can’t See Over the Load Drive in Reverse.
 Drive With Load Approximately Six Inches Above Surface.
 Never Pass Pedestrians - They Must Always Yield Way!
 Remember That the Driving Wheels Are Your Pivot Point.
 Obey Traffic Rules and Local Policies.
 Always Slowdown to Attempt a Turn.
DANGEROUS DRIVING CONDITIONS
LET’S DISCUSS SITE-SPECIFIC PROBLEM AREA’S
SITE SPECIFIC PROBLEM AREAS

AT THIS FACILITY INCLUDE:
 Hazardous (Classified) Operating Locations.
 Closed Environments Poorly Ventilated Areas.
 Unique or Potentially Hazardous Operating Areas.
UNSTABLE FLOOR SURFACES

 Traction Problems, Skidding and Sliding Can Occur.
 Drive Cautiously and at Slow Speeds.
 Be Aware of Debris and Spills.
 Consider Areas Where Contractors May Be Working.
 Avoid Making Tight Turns.
 Ensure Brakes Are Applied Carefully.
OVERHEAD CLEARANCES
 Plan Your Route in Advance.

 Drive Cautiously and at Slow Speeds.
 Know the Mast Height and Facility Overhead Clearances.
 Be Careful Around Electrical Lines.
SPATIALLY RESTRICTED AREAS
 Consider Getting Out Before You Get In.

 Try Moving Empty Forks to One Side of the Carriage.
 Use Maximum Turning Angles.
 Be Careful When Making Tight Turns.
HIGH TRAFFIC AREAS

PEDESTRIAN CONSIDERATIONS
 Never Allow a Pedestrian Between You and a Fixed Object.
 Never Pass a Pedestrian, They Must Yield Right of Way.
 Maintain a Safe Distance When Loading and Unloading.
 Be Careful When Making Tight Turns.
 Never Assume Pedestrians Know You’re Position.
HIGH TRAFFIC AREAS
MULTIPLE FORKLIFT CONSIDERATIONS

 Obey All Local Traffic Rules and Signs.
 Know Where All Mirrors Are Positioned.
 Use Horns When Approaching Corners, Doorways, Aisles.
 Never Exceed the Safe Working Speed of Five Mph.
 Keep a Safe Distance From Other Forklifts (3 Lengths).
 Know Where All Mirrors Are Positioned.
 Pass Only in Authorized Areas.
UNEVEN DRIVING SURFACES

 Understand the Type Tires Installed on the Vehicle.
 Understand the Limitations of The Tires.
 Approach Railroad Tracks at a 45-Degree Angle.
 Take Alternate Routes Rather Than Unnecessary Risks.
 Determine if Different Types of Vehicles Are Available.
LOADING DOCK OPERATIONS

 Ensure Bridge or Dock Plates Are Secure.
 Ensure Bridge or Dock Plates Are Rated for the Vehicle.
 Ensure Trailer, Truck, or Railcar Wheels Are Secured.
 Never Accelerate on Bridge or Dock Plates.
 Always Drive Straight on to Bridge or Dock Plates.
 Always Maintain a Safe Distance From Edges.
 Never Compete With Pedestrians.
TRAILER OPERATIONS
 Ensure the Trailer Floor Is Rated for the Vehicle Weight.
 Verify That the Trailer Floor Is in Serviceable Condition.
 Ensure the Forklift Will Not Unbalance the Trailer.
 Use Additional Trailer Supports If Unbalancing Is a Risk.
 Consider the Interior Trailer Height.
 Ensure the Trailer Cannot Roll Away From the Dock.
 Consider Lighting and Inclement Weather.
LOADED FORKLIFT RAMP OPERATIONS
ALWAYS APPROACH RAMP LOAD FIRST!
REAL HEAVY PARTS
ACME
FORKLIFTS
6500lbs
LOADED FORKLIFT RAMP OPERATIONS
ALWAYS LEAVE RAMP LOAD LAST!
REAL HEAVY PARTS
ACME
FORKLIFTS
6500lbs
UNLOADED FORKLIFT RAMP OPERATIONS
ALWAYS APPROACH A RAMP FORKS LAST!
ACME
FORKLIFTS
UNLOADED FORKLIFT RAMP OPERATIONS
ALWAYS LEAVE A RAMP FORKS FIRST!
ACME
FORKLIFTS
TURNOVERS
LONGITUDINAL TURNOVER
TURNOVERS
LATERAL TURNOVER
LONGITUDINAL TURNOVER
 Usually Best to Leave the Vehicle.

 No Guarantee of Safety During a Longitudinal Turnover.
ACME
FORKLIFTS
LATERAL TURNOVER
 Usually Best to Stay With the Vehicle.
 Hold on to the Steering Wheel and Push Into the Seat.
 No Guarantee of Safety During a Lateral Turnover.
ACME
FORKLIFTS
SPOTTERS
NEVER UNDERESTIMATE
THE VALUE OF A SPOTTER!
ACME
FORKLIFTS
REACH TRUCK SAFETY
GENERAL PRECAUTIONS
 If You’re Not Trained, You’re Not Authorized.

 Use Only on Flat, Stable Floor Surfaces.
 Never Move Vehicle While Elevated.
 Ensure Sufficient Headroom Exists Before Lifting.
 Look for Electrical Obstructions (Lights Etc).
 Engage Parking Brake During the Lift.
 Put Vehicle in Park During Lift.
 Use Spotters Effectively to Enhance Safety.
 Use Appropriate Fall Protection for the Person Being Lifted.
REACH TRUCK SAFETY
ACME
FORKLIFTS
OPERATOR CONTROLLED FORKLIFT ATTACHMENT

REACH TRUCK SAFETY
FORKLIFT ATTACHMENT
 Look Before You Descend.
 Use Within Design Limitations.
 Follow Local Lifting Guidelines.
 Follow Manufacturers Guidelines.
 Ensure Platform Is Secured to Forks.
 Ensure Both Employee’s Are Trained.
 Use a Fall Harness, Not “Safety Belts”.
 Never Exceed Your “Safe Reach” Distance. ACME
 Ensure Fall Prevention Guards Are In Place. FORKLIFTS
 Never Move Vehicle While Platform Is Elevated.

REACH TRUCK SAFETY
OPERATOR CONTROLLED
 Ensure You are Trained.
 Look Before You Descend.
 Use Within Design Limitations.
 Follow Local Lifting Guidelines.
 Follow Manufacturers Guidelines.
 Use a Fall Harness, Not “Safety Belts”.
 Never Exceed Your “Safe Reach” Distance.
 Ensure Fall Prevention Guards Are In Place.
 Never Move Vehicle While Platform Is Elevated.
CONTRACTOR SAFETY REQUIREMENTS
OUTSIDE CONTRACTORS MUST:
 FOLLOW YOUR RULES AND HAVE ADEQUATE TRAINING.
FACILITY OR COMPANY REPRESENTATIVES MUST:
 INFORM THE CONTRACTOR OF INTERNAL POLICIES

AND PROCEDURES.
 ENSURE THAT THE CONTRACTOR(S) ARE FOLLOWING

YOUR PROCEDURES.
TIPS FOR USING CONTRACTORS
 Remember, You Control Your Facility!

 Review Their Procedures With Them!
 Review Their Procedures Before They Start the Job!
 Determine Their Safety Performance Record!
 Determine Who Is in Charge of Their People!
 Determine How They Will Affect Your Employees!

Forklift Safety

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FORKLIFT SAFETY

OSHA 29CFR 1910.178

 Understand Safety Regulations Regarding Forklifts.

29CFR - 1910 - 178

29CFR - Safety and Health Standards

1910 - General Industry

178 - Powered Industrial Trucks

APPROXIMATELY 34,000 RELATED INJURIES A YEAR:

 Overloading Causing the Vehicle to Turnover.

NARRATIVE: AN EMPLOYEE WAS SPOTTING A FORKLIFT

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL

CITATION: FAILURE TO MAINTAIN CLEARANCE BETWEEN THE

NARRATIVE: AN EMPLOYEE WAS TRANSFERRING MATERIAL

CITATION: FAILURE TO MAINTAIN VEHICULAR CONTROL

HOW THIS COURSE IS STRUCTURED:

MEASUREMENT OF OPERATORS PERFORMANCE:

TRAINEES MAY OPERATE A FORKLIFT ONLY:

1. Under the Direct Supervision of Persons Who Have the

2. Where Such Operation Does Not Endanger the Trainee or

TRAINEES MUST BE PROPERLY TRAINED:

4. Evaluation of the Operator's Performance in the Workplace.

TRUCK TOPICS TO BE ADDRESSED:

TRUCK TOPICS TO BE ADDRESSED:

WORKPLACE-RELATED TOPICS TO BE ADDRESSED:

RETRAINING IS REQUIRED WHEN:

ELEMENTS OF THE PROGRAM:

1. Written Company Safety Procedures.

WRITTEN COMPANY SAFETY PROCEDURES:

1. Company Forklift Policy Reviewed Annually.

SETTING UP THE PATTERN:

 Aisles Must Be Well-Lighted and Obstruction Free.

DEPT - A DEPT - B DEPT - C DEPT - D OFFICE

DEPT - E DEPT - F DEPT - G DEPT - H

VARIOUS TYPES OF FORKLIFT CONFIGURATIONS:

NOTE: YOU MUST ENSURE THAT THE TYPE OF

- USED WITH HEAVIER LOADS

CONSULT YOUR VEHICLE OWNERS MANUAL

- INDOORS OR SMOOTH SURFACES

CONSULT YOUR VEHICLE OWNERS MANUAL

AUTO STEERING VERSES FORKLIFT STEERING:

AUTO STEERING VERSES FORKLIFT STEERING:

AUTO STEERING VERSES FORKLIFT STEERING:

DANGER ZONE FORKLIFT

THE RATED CAPACITY

OPERATING NEAR PEDESTRIANS

COUNTER PIVOT POINT PIVOT POINT COUNTER WEIGHT

MOVING THE LOAD AWAY FROM

CONSULT YOUR VEHICLE OWNERS MANUAL

REAL HEAVY PARTS REAL HEAVY PARTS

CONSULT YOUR VEHICLE OWNERS MANUAL

REAL HEAVY PARTS

MOVING OR TURNING THE VEHICLE

FORKS SHOULD BE SPREAD AS

TYPES OF POWER SOURCES

CONSULT YOUR VEHICLE OWNERS MANUAL

INSPECTION OF POWER SOURCES

CONSULT YOUR VEHICLE OWNERS MANUAL

BATTERY SAFETY PRECAUTIONS

CONSULT YOUR VEHICLE OWNERS MANUAL

BATTERY SAFETY PRECAUTIONS

CONSULT YOUR VEHICLE OWNERS MANUAL

BATTERY FILLING PRECAUTIONS

HANDLING BULK ELECTROLYTE