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

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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
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 Load’s
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 load is located 300LB

• Pick up load on the CENTER OF GRAVITY

side closest to its LOAD CENTER

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

© 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

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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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What’s Wrong Here?

Forks not fully lowered

Forklift parked on
sloped surface
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

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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
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

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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 load’s
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
• Don’t 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

© 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

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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
• Don’t 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 gas
—do 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.

© BLR®—Business & Legal Resources 1202

 Test your Knowledge
1. The first step toward safe WORD BANK
forklift operation is to conduct
a _____________
preoperational _________. preoperational inspection
inspection
battery test
2. Your inspection should continue
when you are in the _________
operator’s operator’s seat
seat
____. warehouse

3. Only authorized
__________ drivers
______ authorized drivers
should operate a forklift. supervisors
jump
4. If you are in a tipover, never
try to jump
____. remain seated
low
5. When traveling in a forklift,
high
keep the forks low
___.
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
© BLR®—Business & Legal Resources 1202