Folk Lift Operator Safety

SHIFANA OTTATHAIKAL KAREEM
https://www.linkedin.com/in/shifana-ok
FORKLIFT OPERATOR
SAFETY TRAINING

SAFE OPERATION OF FORKLIFTS

The risk of ignoring forklift safety Fatal Accident Type %
Forklifts are extremly useful in a Crushed by vehicle tipping over 42%
variety of workplaces, but there is Crushed between vehicle and a surface 25%
greater risk of property damage, Curshed between two vehicles 11%
injury or death if you:
Struck or runover by a forklift 10%
Are not trained on forklift safety. Struck by falling material 8%
Are not familiar with specific Fall from platform on the forks 4%
forklift vehicle.
Approx. 35,000 serious injuries &
Operate the forklift in an unsafe 62,000 non-serious injuries involving
manner forklifts occur every year. OSHA
Operate the forklift in with a estimates 11% of all forklifts are
defect or missing parts. involved in accidents every year.
COMPARING FORKLIFT TO AN AUTOMOBILE

Forklifts usually steers from the rear rather than the front making it swing wide.
Carries heavy loads often in tight places and rough terrain.
Can have reduced visibility.
Can have a high center of gravity making it susceptible to turnover.
Controls are different and more complicated.
Heavier than most cars and trucks.
Forklifts Rear is heavy to
balance loads on forks.
Unlike cars with brakes on
all 4 wheels, forklifts
typically have brakes only
on front drive wheels.
Due to limited braking,
forklifts require slower
speeds for safe operation.
This Doesn't operate like these
TYPES OF FORKLIFT
Warehouse forklift Side loader Counterbalance Forklift

Loading Capacity: Sideways compartment Evenly distributes vehicle's
1 to 5 tons that moves in the direction weight while carrying heavy
Best for transporting items of the load. loads.
between short distances. Lifting heavy, bulky and Offers 360 degree rotation.
long items in tight spaces.

https://www.linkedin.com/in/shifana-ok Image Credit: bigrentz.com
TYPES OF FORKLIFT
Telehandler Heavy duty forklift Rough terrain Forklift

Extendable arm Hydraulic levers combine Sturdy design with oversized
attachment and a balance of reach and tires and a reinforced cage
articulating boom. power. cab.
Lifting loads off the ground Transporting heavy loads Outdoor jobs with uneven,
to higher elevations. for industrial applications. rocky ground.
TYPES OF FORKLIFT
Pallet jack Walkie stacker Order picker

Compact size, powered Unique design requires Open operator window and
manually or occasionally the operator to walk no pallet handling.
with a battery. behind the truck. Piece-picking units and
Maneuvering small loads Maneuvering pallets to warehouse inventory
— like pallets — in tight greater heights than is applications.
spaces and over short possible with a pallet jack.
distances.
FORKLIFT CLASSIFICATIONS
Class I Electric Motor Ride Truck Class v Internal combustion engine
Fuel Type: Battery trucks with pneumatic tires
Use: Indoor settings such as warehouses Fuel Type: Gas or Diesel
Use: Indoor and outdoor with rough
Class II Electric Motor Narrow Aisle Truck surfaces
Fuel Type: Battery Class Vi Electric & internal Combustion
Use: Moving inventory in narrow or tight engine tractors
spaces Fuel Type: Battery,Gas or Diesel
Use: Hauling or Towing Loads
Class III Electric Motor Hand Truck
Fuel Type: Battery Class VII Rough terrain forklift truck
Use: Quickly unloading delivery trucks across Fuel Type: Gas or Diesel
short distances
Use: Construction sites, uneven ground,
Class IV Internal Combustion Engine with high-elevation lifting
Cushion Tyres
Fuel Type: Gas or Diesel
Use: Low Clearence situations
SHIFANA OTTATHAIKAL KAREEM https://www.linkedin.com/in/shifana-ok
PARTS OF A FORKLIFT
Image from Conger Industries
Standard forklifts vary in types; all use
hydraulic fluid for operation.
Most have a large rear counterweight to
balance front loads.
Overhead guard: Equipped to protect
operators from falling objects.
Lifting mechanism: Forks and mast,
powered by the motor, perform main
lifting tasks.
Hydraulic fluid leak: Older forklifts may
develop leaks, affecting fork operation,
especially under load.
Hydraulic fluid puddles on cement floors
pose slipping risks.

Image from Bigrentz.com
DAILY CHECK
RECOMMENDATIONS
Test operating controls such as brakes,
lights, horn and steering wheel.
Check mast and overhead guard for
damage.
Examine tire and fluid levels (hydraulic,
brake, engine, fuel and coolant).
Check for water, oil or radiator leaks.
Ensure the forks are in good condition
(e.g. straight, no cracks, no distortion).
Look for potential hazards.

FORKLIFT NAMEPLATE
A Model Number
Essential for dealership communication, lift
A D capacity, and accessing online resources.
G K J
H
B B Fuel Type
E Indicates power source: electricity (E),
C
liquid propane (LP), diesel (DS), gasoline
(G), or compressed natural gas (CNG).
F
C Truck Weight
Total weight of the forklift.
I D Serial Number
Vital for technician communication, parts
matching, and machine understanding.
The nameplate will list the type of forklift and the capacity.

FORKLIFT NAMEPLATE
E Tire Size I Operator Training
Specifies tire type and size for replacement Only trained individuals who have read and
compatibility (e.g., "Solid" or "Cushion"). understood the manual should operate forklifts.
F Forklift Diagram J Attachments
Provides key data points for understanding lift Indicates added features like side-shifters for
capacity, maneuverability, and load center enhanced capabilities.
information.
K Back Tilt
G Mast Type Represents mast tilt degrees for load security (e.g., 6
Various types including 2-stage, 3-stage, and 4- degrees).
stage based on specific model and
requirements.
H Front Tread
Equivalent to overall width, crucial for
workspace planning.

FORKLIFT STABILITY TRIANGLE

The stability triangle forms by Max loaded forklift centre of gravity
connecting 3 points:
the two front wheels and the center
point of the rear axle. Unloaded
For the forklift to remain balanced, the forklift
forklifts center of gravity must stay center of
within the triangle. gravity
How loads affect forklifts?
Forklift balances a load with a Image from Bigrentz.com
counterweight at the back.
Front wheels act as a fulcrum or As the load is raised up and away, the center of
balance point. gravity also shifts up and away from the middle of
The center of gravity moves upward forklift. If it moves outside the triangle formed by the
when the forks are raised. front wheels & the center of the rear axleaxle, the
SHIFANA OTTATHAIKAL KAREEM forklift will tip forward & fall to the side.
HOW LOADS AFFECT FORKLIFT?

Forklift balances a load with counterweight at the back.
LOAD Front wheels act as a fulcrum or balance point.
Center of gravity moves when the forks are raised.
Fulcrum: The point on which a lever rests and

where it pivots.
Center of gravity: The point where the weight
of something is concentrated and where it
must be supported to achieve equilibrium.
COUNTERWEIGHT FULCRUM Load center: The distance from the face of the
forks on the forklift to the load’s center of
gravity.

HOW LOADS AFFECT FORKLIFT?

A forklift with a raised load tends to be unstable
especially with a load near forklifts lifting capacity.
Hence as soon as the load is picked off the upper shelf

in this image the load must be lowered before Don't travel with a raised load
traveling or moving forward or backward.
As the load is raised up and away the center of

gravity also shifts up and away from the middle of
forklift.
If it moves outside the triangle formed by the front

wheels and the center of the rear axle, the forklift will
tip forward or fall to the side.

FORKLIFT LOAD CAPACITY

While carrying a load near the
maximum allowable capacity, be

aware of the following:
Danger of tip over
Danger of losing load
Image from Bigrentz.com Danger of being struck by falling
Moving the load load
Caution with near-maximum loads:
Exercise extra care.
Tilt mast and forks: Position heaviest part
against carriage for stability.
Travel with tilted-back mast: Maintain
load stability during movement.
Avoid forward tilt during travel: Increases
load distance and reduces stability.
DRIVING ON AN INCLINE
More reasons why forklifts tip over

Driving too fast around a corner.
Driving off edge of platform, ramp,
road or other surface.
Driving an indoor forklift outdoors
Going up the ramp with Going down the ramp on rough uneven ground outdoors
a load with a load Operating on an incline or hill.
In Case of Tip Over
Going up the ramp Going down the ramp

Lean away Hold onto steering Dont jump
without a load Image from Bigrentz.com
without a load & brace feet
INSPECTION & MAINTENANCE
All forklifts must be examined at least daily before being used. Forklifts used on a round
the clock basis must be examined after each shift.
01 Fluid levels- oil, water and hydraulic fluid.

Leaks, cracks or other visible defect in hydraulic
02 hoses and mast chains
Tire pressure, tire cuts or gouges
03
Condition of the forks, including the top clip
04 retaining pin.
05 Safety decals and nameplates in place and
legible
06 All safety devices working properly including the
seatbelt.
A vehicle that is dagamed, defective or unsafe must be
removed from service. Report the problem to your
supervisor immediately.
PROPANE POWERED FORKLIFT REFUELING

Liquid propane is extremely cold when
released to the atmosphere. If your skin is Propane powered forklifts and

exposed while refueling you can get frostbite. Carbon Monoxide
These type of forklifts produce
Shut off the engine while refueling carbon monoxide.
The amount depends on how well
Don't leave the forklifts near high heat sources they are tuned, but must be 1% or
less at the tailpile.
Turn the tank valve off when parking for long
period of time. Carbon monoxide poisoning may
result from propane forklift use in
Take any propane leak seriously as its heavier- enclosed spaces lacking sufficient
than-air vapor tends to accumulate in low-lying ventilation; thus, indoor propane
areas and can ignite with a spark or flame if forklifts require regular tuning and
not dispersed adequately. periodic carbon monoxide emission
testing.
https://www.linkedin.com/in/shifana-ok SHIFANA OTTATHAIKAL KAREEM
CHARGING/CHANGING BATTERIES ON ELECTRIC

FORKLIFT
The battery changing/ charging area should have the When changing or charging
following: electric forklift batteries,
there's a risk of burns from
battery acid or fire from
hydrogen gas; as batteries
are heavy, they're often lifted
No smoking Adequate fire An eyewash that with a hydraulic hoist,
signs protection provides at least 15 mins requiring proper operation
of flowing water knowledge.
Ventilation to remove hydrogen Plenty of water for flushing &

gas during battery charging. neutralising spilled battery acid.
STACKING LOADS ON PALLETS

Block Brick Pinwheel

Stack boxes in a block like Stack boxes in alternating Stack boxes on the
formation, one box on top interlocking pattern in each pallet with some gaps
of the other, utilizing the layer like a brick wall. in between in an
column method. interlocking method to
create a wheel shape.
Loose loads are subject to falling. Off Avoid using damaged
center loads can also be subject to falling pallets
or cause the forklift to tipover. SHIFANA OTTATHAIKAL KAREEM
FORKLIFTS & PEDESTRIANS

Slow down and sound horn at intersections,
corners and whenever your vision is obstructed. Slow down Sound horn Flash warning
When provided use flashing warning light or light
backup alarms when traveling in reverse.
Always look in the direction of travel. You are often moving faster
than a pedestrian and
Signal to pedestrians to stand clear. forklifts can't stop suddenly
especially with a load. 10%
DO NOT allow anyone to stand or walk under of all fatalities involving
upraised forks. forklifts are from workers
being struck or run over by
When possible make eye contact with a forklift.
pedestrians or other forklift operators before Don't let it be your fault.
moving in their path.
LOADING TRUCK TRAILERS & RAILROAD CARS

Make sure: Driving in and out of trailers or railcars
Truck trailer wheels are chocked. can cause movement.
Dock board is secure and can handle Securing truck trailer wheels prevents
weight. shifting and ensures dockboard stability.
You use horn or warning lights when Various methods are available for
exiting trailer or railcar. securing dockboards or bridgeplates.
WIDE OR IRREGULAR SIZE LOADS

Distribute the weight evenly when Wide loads are prone to shifting,
carrying irregular size load. complicating maneuvering.
Keep the center of gravity of the load Irregular sizes can shift center of gravity
as near as possible to the center going unexpectedly, requiring caution.
horizontally across the forks. For safety, moving wide, heavy loads
as near to the front wheel as possible. with a crane is often preferable to a
forklift.
FORKLIFT DO'S & DON'TS


No one else on the forklift except
the operator, unless the forklift has
a seat for a rider.
Always drive with the forks Watch overhead clearences- especially

lowered and lower the forks to entering or exiting buildings or when you are
floor when parking the forklift. raising a load on the forks.
Don't leave your forklift unattended

Safety protocols for unattended forklifts:
Lower forks, Neutralize controls, Shut off power,
Set brakes, Block wheels if parked on an incline.
THANK YOU!
ICONS FROM ICONFINDER & FLATICON
IMAGE CREDIT: BIGRENTZ
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SHIFANA OTTATHAIKAL KAREEM

SHIFANA OTTATHAIKAL KAREEM

SAFE OPERATION OF FORKLIFTS

COMPARING FORKLIFT TO AN AUTOMOBILE

Warehouse forklift Side loader Counterbalance Forklift

SHIFANA OTTATHAIKAL KAREEM

Telehandler Heavy duty forklift Rough terrain Forklift

Pallet jack Walkie stacker Order picker

SHIFANA OTTATHAIKAL KAREEM

SHIFANA OTTATHAIKAL KAREEM

SHIFANA OTTATHAIKAL KAREEM

SHIFANA OTTATHAIKAL KAREEM

FORKLIFT STABILITY TRIANGLE

HOW LOADS AFFECT FORKLIFT?

Fulcrum: The point on which a lever rests and

SHIFANA OTTATHAIKAL KAREEM

HOW LOADS AFFECT FORKLIFT?

Hence as soon as the load is picked off the upper shelf

As the load is raised up and away the center of

If it moves outside the triangle formed by the front

SHIFANA OTTATHAIKAL KAREEM

FORKLIFT LOAD CAPACITY

maximum allowable capacity, be

More reasons why forklifts tip over

In Case of Tip Over

Going up the ramp Going down the ramp

01 Fluid levels- oil, water and hydraulic fluid.

PROPANE POWERED FORKLIFT REFUELING

released to the atmosphere. If your skin is Propane powered forklifts and

CHARGING/CHANGING BATTERIES ON ELECTRIC

Ventilation to remove hydrogen Plenty of water for flushing &

STACKING LOADS ON PALLETS

Block Brick Pinwheel

FORKLIFTS & PEDESTRIANS

LOADING TRUCK TRAILERS & RAILROAD CARS

WIDE OR IRREGULAR SIZE LOADS

FORKLIFT DO'S & DON'TS

Image from Bigrentz.com

Always drive with the forks Watch overhead clearences- especially

Don't leave your forklift unattended

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