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© BLR®—Business & Legal Resources

Forklift Operator Safety

Massachusetts Retail Merchants Workers’ Compensation Group, Inc.

Safety Awareness For Everyone from Cove Risk Services


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


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


Nameplate

– OSHA requires a legible nameplate

– It includes information about the forklift and attachments

– It lists the maximum load capacity

– It describes the load centerImage Credit: State of WA-WISHA ServicesImage Credit: State of WA-WISHA Services


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


Stability Triangle

Vehicle Center of Gravity (unloaded)

Center of Gravity of Vehicle and Maximum Load (Theoretical)

Stability Triangle


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


Attachments

Image Credit: CDC

– Change operating clearances

– Change capacity

– Change stability and load center


Operating Hazards—Pedestrians

Accidents involving pedestrians may be caused by:

– Obstructed view– Turning– Speeding– Pedestrian unaware

forklift is present– Carrying passengers

and horseplay


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


Operating Hazards—Load Carrying

– Working around loading docks

– Loads that block the forward vision

– Stacking and unstacking on racks


What’s Wrong Here?

Forklift parked on sloped surface

Forks not fully lowered


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


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


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


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 equipment


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


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


Traveling

– Look in the direction of travel

– Keep body inside cage

– Keep forks low when traveling

– Sound the horn

– Don’t speed

– Check clearance


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


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


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


Parking

– Don’t block exits or aisles

– Lower the forks

– Set gear to neutral

– Set the parking brake

– Turn off the key


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


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


Inspection, Operation, and Maintenance—Questions?

– Inspection procedures?

– Operating procedures?

– Vehicle maintenance?


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

Massachusetts Retail Merchants Workers’ Compensation Group, Inc.

Safety Awareness For Everyone from Cove Risk Services

© blr ® —business & legal resources forklift operator safety massachusetts retail merchants...

Documents

forklift slide

load center slide

tipover slide

lowered slide

horseplay slide

workplace slide

material slide

forklift training