Safety Training Presentations

1. Safety Training Presentations FORKLIFT OPERATOR SAFETY TRAINING

3. Forklift Operator Training • Who needs forklift training? • Anyone who operates a forklift • Who must conduct the training? • A knowledgeable trainer • Why is training necessary? • Forklifts pose many hazards • Approx. 100 deaths and 38,000 injuries/year • Most Common accidents: • Tip over • Struck by lift or struck by load

4. Forklift Safety Hazards • Forklifts are very heavy • Average automobile - 1,000 - 2,000 lbs. • Average forklift - 4,000 - 8,000 lbs. • Loads can be heavy • Too heavy to lift by hand • Forklifts or their loads can be unstable • Forklifts can roll over easily • Loads can fall off forks or cause roll over

5. Pre-Use Inspections • Inspect forklift before each use • Don’t know condition left in by last user • Not inspecting the forklift prior to use could lead to a hazardous situation or cause serious damage to the forklift and/or the load

6. Brakes Steering Horn Lights Oil Coolant Battery/LP Tank Hoist Forks Engine/Drive Motor Tires Misc. Cage Seat belt General overall condition of the forklift Pre-Use Checklist

7. Pre-Use Inspection - Lift Mechanisms • Inspect mast for damage • Broken or cracked weld point • Make sure roller tracks are greased and free to travel • Inspect forks • Cracks on ends, along blades or at heels • Make sure not bent • Check hydraulic lines and fluid levels

8. Pre-Use Inspection - Lift Mechanisms • Inspect all lift and tilt cylinders • Leaks • Mounting hardware • Inspect tires • Excessive wear • Proper inflation (if not solid rubber)

9. Propane Tank Inspection • Inspect cylinder for damage • Cracks and broken weld points • Inspect • Valves, nozzles and hoses • Be aware of flammability • Three ways to detect leaks • listen for gas escaping • smell odor • look for frost on the coupling

10. Changing Propane Tanks • No smoking! • Shut off cylinder valve before turning off forklift to reduce pressure in the fuel line • Liquid propane is approx. -40 degrees • Wear heavy duty rubber gloves • Wear safety glasses • Make sure pressure relief valve points straight up when replacing the tank

11. Battery Charging • Inspect batteries for worn parts and cables • Beware of acid • No smoking • Wear faceshield, goggles, apron, rubber gloves • Only add water after charging • Make sure charger is off before disconnecting the battery • Remove all jewelry • Use hoist or roller system when replacing

12. Capacity Plates • Must be on all forklifts • If missing or illegible, replace • Information found on capacity plates • Model # • Max load weight • Max lift height • Serial # • Manufacturer information

13. Starting the Forklift • Apply the foot brake • Shift gears to neutral • Turn the key • Check gauges and indicators • Check controls, steering and brakes for smooth operation

14. Operating the Forklift • Know locations and functions of all controls and gauges • Be aware of what is going on around you • Be aware of potential problems with the forklift • Be sure path of travel is free from hazards • Traveling speed in doors should not be any faster than a quick walking pace

15. Handling and Moving Loads • Check the Capacity Plate to be sure the forklift can handle the load • Check the load for weight and stability • If load is not marked • Contact distributor/shipper of the load • Lift the load 1-2 inches to test the stability of the rear wheels and the forklift • If the forklift struggles, set the load down and if possible break load into smaller, more manageable loads

16. Stability Triangle

17. Stability Triangle • The closer the center of gravity (CG) is to line BC the more stable the forklift is • The closer the CG is to lines AB or AC the more unstable the forklift becomes • If the CG ever goes outside the stability triangle, the forklift can tip • Loads too heavy or offset • Taking corner too fast • Traveling surface is not level

18. Fulcrum Point • The front wheels of the forklift are the fulcrum point • The rear of the forklift has counter weights to help off set the weight of the load • Unloaded forklift is unstable - all the weight is in the rear • When the forks are loaded the weight of the forklift and load are more evenly balanced • Loaded forklift is more stable • When the load out weighs the counter weight the forklift can tip forward when the load is raised

19. Tipping Forklift • What should you do? • Must be wearing seatbelt • Will keep you from falling out of caged area • Hold tightly to steering wheel with both hands • Keep hands and arms inside caged area • Plant feet flat on floor and press down • Keeps body stable and keeps legs in caged area • Lean in opposite direction

20. Handling and Moving Loads • Picking up load • Approach the load straight on with the forks in the travel position • Stop when the fork tips are approx. 1 foot away from the load • Level forks and drive slowly forward until load is against backrest • Lift the load high enough to clear what is under it

21. Handling and Moving Loads • Picking up load (cont.) • Look over both shoulders to make sure you are clear and slowly back out one foot • Sound horn before backing if can’t clearly see behind you • Slowly tilt mast back to stabilize the load

22. Handling and Moving Loads • Setting down the load • Drive to location, square up to load area and stop about one foot away • Level the forks and slowly drive forward • Lower the load • Tilt the forks slightly forward • Look over your shoulders and back straight out until the forks clear the load

23. Stacking and Unstacking • Lifting a load • Approach the load slowly with the forks in the travel position • Stop approx. one foot away from the load and raise forks to correct height • Level forks and drive forward until load is flush against backrest

24. Stacking and Unstacking • Lifting a load (Cont.) • Lift high enough to clear the bottom load, look over both shoulders to see if clear to back and slowly back straight out • After clearing top of stack, stop and lower mast to travel position • Tilt forks back • Proceed to destination

25. Stacking and Unstacking • Stacking a load • Approach placement area slowly and square • Stop about one foot away and lift mast high enough to clear the placement area • Move forward slowly until the load is square over the stack • Level the forks and lower the mast until the load is resting on the stack • Slowly back straight out

26. Stacking and Unstacking • Additional tips • Never lift a load while moving • Stop completely before raising the mast • Make sure the top load is squarely stacked on bottom load • Always approach and leave the load area slowly • Always look over shoulders before backing up

27. Driving with a Load • Travel with load tilted slightly back for stability • Travel with the load at the proper height • 4-6 Inches at fork tips • 2 Inches at heels • Drive in control • Drive in reverse if you cannot see over the load

28. Driving on Inclines - Ramp/Slope • Always drive with the heavier or less stable end of the forklift pointing up the incline • If the forklift is loaded (heavier/less stable in front) • Drive forward up the incline with the load • Drive in reverse coming down the incline with the load pointed up the incline • If the forklift is not loaded (heavier in rear) • Drive forward down the ramp • Drive in reverse going up the ramp

29. Stopped Forklift • When Parked or unattended • Forks flat on ground • Turn off engine • Set parking brake • Do not block: • Exits • Emergency equipment • Signs or postings

30. Pedestrians • Pedestrians have the right of way • Slow down at intersections • Look before backing • Use horn when coming around blind corners and at blind intersections • Check mirrors at intersections if they are present in workplace • Pedestrians must be cautious in areas where forklifts may be operating

31. Conclusion • Forklifts are more hazardous than most people usually perceive them to be • Pre-use inspections must be performed before each shift • It is important to understand how the load will affect the stability of the forklift • The operator must always be on the look out for hazards and pedestrians