Forklift Operator
Safety
Session Objectives
You will be able to:
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
Understand the hands-on portion of the
training
Why Forklift Training Is
Necessary
100 fatalities each
year
20,000 lost workday
injuries annually
Common injuries
Hitting a pedestrian
Tipping over
Falling from raised
forks
Falling from a ladder
struck with a forklift
Falling material
Training reduces
injuries
Powered Industrial Truck
Defined
Any mobile power-propelled truck used to
carry, push, pull, lift, stack or tier materials.
Powered industrial trucks can be ridden or
controlled by a walking operator.
Excluded
Vehicles designed for earth moving or over the
road haulage. Equipment that was designed to
move earth but has been modified to accept
forks are also not included.
Vehicles Covered Include
High lift trucks Pallet trucks (electric)
Counter-balanced Narrow aisle rider
trucks trucks
Cantilevered trucks Straddle trucks
Rider trucks Reach rider trucks
Forklift trucks Single side loader
High lift platform rider trucks
trucks High lift order picker
Low lift trucks rider trucks
Low lift platform Motorized hand/rider
trucks trucks
Motorized hand trucks Rough terrain trucks
Forklift Fatalities
What age group has the highest
number of
fatalities?
D) 18 – 24
E) 25 – 34
F) 35 – 44
G) 45 – 54
Fatalities by Age Group
12%
5% Under 20
3%
21% 20 - 24
25 - 34
10%
35 - 44
45 - 54
56 - 64
65 & over
22%
27%
Regulatory
Requirements
According to 29 CFR 1910.178:
Operator must receive training before
operating a forklift
Demonstrate competency
Forklift characteristics
Operating environment
Inspection and maintenance
Forklift Basics
www.Lni.wa.gov
Image Credit: State of WA-WISHA Services
Forklift Characteristics
Different from
driving a car
Rear of a forklift
swings in opposite
direction of the turn
Forklift impact
against objects
magnified
Driven backward as
well as forward
One hand on
controls
2 - 3 times the
weight of a car
Image Credit: State of WA-WISHA Services
Nameplate
OSHA requires a
legible nameplate
It includes
information about
fork modifications
and attachments
It lists the
maximum load
capacity
It describes the
Image Credit: State of WA-WISHA Services
load center
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 loads at the
shortest distance
from the edge of
the item to the
item’s center of
gravity and load
center
Image Credit: State of WA-WISHA Services
Stability Triangle
Stable forklift
without a load
Stable forklift with
maximum load
Unstable forklift
with offset
maximum load
Combined Actions
Center of gravity
(COG) side to side
COG forward
COG backward
Combination of two
can cause tip-over
Vertical Stability
Attachments – Approved
OSHA Safety Cage
Change operating
clearances
Change capacity
Change stability
and load center
Image Credit: State of WA-WISHA Services
Operating Hazards—
Pedestrians
Forklift accidents
involving
pedestrians may
be caused by:
Obstructed view
Turning
Speeding
Pedestrian unaware
forklift is present
Carrying
passengers and
horseplay
Operating Hazards—
Environmental
Conditions
Operating non-
electric forklift in
poorly ventilated
area
Traveling on ramps
Crossing railroad
tracks
Slippery floors
Operating on dirt or
gravel
Poor lighting
Operating Hazards—Load
Carrying
Load-carrying
hazards include:
Working around
loading docks
Loads that block
the forward vision
Stacking and un-
stacking on racks
Leaving A Forklift
Unattended
Unattended means: the
operator is more than 25
feet away or the forklift is
out of view.
1. Lower the forks to the
ground!
2. Set the controls to
neutral.
3. Turn off the power.
4. Set the brakes.
If you dismount a forklift
Forklift Characteristics
and Hazards—Any
Questions?
Any questions about the characteristics
or basic features of a forklift?
Any questions about the stability of
forklifts?
Any questions about the hazards
specific to our workplace?
Conduct a
Preoperational
Conduct a
Inspection
preoperational
inspection
Follow the
inspection checklist
Complete and sign
the checklist
Inspection Walk-around
Check that the forklift is properly
disengaged—forks down, key off,
neutral gear, parking brake on
Check left and right side—tires, lug nuts,
axle, overhead guard, and no debris
behind the mast
Check front—forks, hoses, fork pins,
backrest, mast, and chains
Check rear—counterbalance and
radiator
Inspection Walk-around
(cont.)
Propane/Gas/Diesel-powered forklift
Check all oil and fluid levels
Check fan belt, fan, and radiator
Check tank, hose attachments, and tank
clamp
Electric-powered forklift
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
Tip-Over Safety
Procedure
Always wear your
seat belt
Hold onto the
steering wheel
Brace your feet
Lean away from
the fall
Image Credit: State of WA-WISHA Services
Loading and Unloading
Never over-load the
forklift
Check the weight of
the load
Locate the load’s
center of gravity
Inspect the load
(stability) www.lni.wa.gov/Safety
Restack unstable
loads Image Credit: State of WA-WISHA Services
Tow from the rear
towing pin
Picking up the Load
Approach the load slowly and straight on
Ensure the forks are centered to evenly
distribute the weight of the load
Make certain the load is balanced and
secure
Drive forward until the forks are into the
load all the way so the load is resting
against the carriage
Raise the load high enough only to clear
the traveling surface, then tilt the mast
back
Traveling
Look in the
direction of travel
Keep body inside
cage
Keep forks low
when traveling
Sound the horn
Don’t speed
Check clearance
Keep the load tilted
back slightly
Image Credit: State of WA-WISHA Services
Traveling (cont.)
Avoid loose objects or holes
Keep the load tilted back slightly
Never carry passengers
Pedestrians always have the right-of-
way
Keep a safe distance from the edge of
ramps or docks
Never EAT, DRINK OR SMOKE!!!!
No horseplay
Placing a Load
Inspect the area for
load placement
Stop and slowly
raise the load to
desired height
Place the load
squarely
Look and then back
up slowly
Ramps and Railroads
No turns on a ramp
Load facing
upgrade
Go slow
Never park on a
dock ramp!!
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 by the
tractor or a fixed
jack
Parking
Don’t block exits or
aisles
Lower the forks
Set gear to
neutral
Set the parking
brake
Turn off the key
What’s Wrong Here?
Identify the hazards
What’s Wrong Here?
What’s Wrong Here?
What’s Wrong Here?
What’s Wrong Here?
Propane Refueling
Highly flammable
gas—do not smoke
Report leaks
immediately
Distinct odor
Hissing sound
Frost on fittings
Use gloves and
safety glasses
Have fire
extinguisher nearby
Propane Refueling
(Cont.)
Turn off the forklift.
Put on PPE
Close the valve.
Turn on the forklift – let the line
bleed out.
Disconnect tank and replace with a
full tank.
Make sure the valve connection is
secure.
Open the valve.
Battery Charging
Charge batteries only in
protected areas with
ventilation
Inspect battery
connectors for damage
No smoking
Immediately clean up
electrolyte spills
Battery electrolyte is
highly corrosive—wear
PPE
Have fire extinguisher
nearby
Gas & Diesel
Turn the engine "OFF" and
apply the hand brake before
refueling.
Clean up any spilled fuel
before restarting the engine.
Make sure the gas cap is
replaced before the unit is
started.
NO SMOKING
Have fire extinguisher nearby
Carbon Monoxide Poisoning
Internal combustion engines produce
carbon
monoxide. This gas can rapidly build up in
any
indoor area. People can be overcome
without
even realizing they are being exposed.
Confusion,
headache, dizziness, fatigue, and
weakness may
set in too quickly for victims to save
themselves.
Carbon monoxide poisoning can cause
permanent brain damage, including
Inspection, Operation,
and Maintenance—
Questions?
Any questions about inspection
procedures?
Any questions about operating
procedures?
Any questions about vehicle
maintenance?
Manual Hydraulic Pallet
Jacks
Place the load evenly
Walk slowly
Back down inclines and into closed
spaces
Make sure the wheels and hydraulic
handles are operating correctly.
Add lubrication when necessary.
Check lift mechanism
Never ride on a pallet jack
Do not use forks as levers or as pry
bars.
Do not use a narrow jack to move a
wide load.
Do not use if:
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
References
www.osha.gov
www.ini.wa.gov/safety/defualt.asp
BLR
