The Premier Resource for Environmental, Health, and Safety Training Solutions

1. The Premier Resource for Environmental, Health, and Safety Training Solutions

2. ForkliftOperationsSafety Driven

3. Introduction Remember when you got your first set of wheels? For most of us, there was a learning curve and a few challenges with staying upright.

4. Introduction Then we got older and other drivers only complicated things. As our skills continued to develop, we took on new challenges, but not without some bumps along the way. Fortunately, those were only minor mishaps back then. But it’s different today. If you’re a professional forklift driver, your experience, skill and good judgment are critical to preventing serious injury Remember when you got your first set of wheels? and maintaining a safe work environment.

5. Introduction Forklifts are a common sight in most factories and warehouses, used to carry, push, pull, lift and stack loads efficiently and with less strain on workers, but, unfortunately, many workers underestimate how dangerous forklifts can be.

6. Introduction If you drive a car it’s a mistake to assume you already know all you need to know to drive a forklift – there are significant differences between the two vehicles. For example, forklifts tip over much more easily than cars do. Adding to the risk, the average forklift weighs about 9,000 pounds, or about three times more than the average car.

7. Introduction Obviously, staying stable and upright are extremely important, and forklifts are counterweighted in the back to balance out the load being carried at the front, but critical to your safety is knowing how to handle that load and staying within the weight capacity of your forklift. Another important difference from automobiles is that forklifts steer from the rear wheels.

8. Introduction This is valuable in warehouse and factory settings because it allows forklifts to make very tight turns – but it also means that it’s that much easier to tip a forklift over if it’s turned while traveling at too high a speed.

9. Introduction According to the Bureau of Labor Statistics, “each year nearly 100 workers are killed in forklift accidents” and “another 20,000 workers are seriously injured.” The most common causes of forklift-related fatalities are: forklifts overturning (22 percent), forklifts striking a pedestrian (20 percent), drivers or other employees being crushed by a forklift (16 percent), and drivers falling from their forklift (9 percent). To prevent accidents like these, the Occupational Safety and Health Administration, or OSHA, mandates that every forklift operator must be properly trained and certified before using the equipment.

10. Daily Inspections Even if you operate your forklift in a safe manner, if the equipment itself is defective or damaged it can put you and your co-workers at risk.

11. Daily Inspections For this reason, forklifts must be inspected at the start of each shift. Because forklifts and other powered industrial trucks vary in design and may be powered by battery, internal combustion or liquid propane, for the complete, specific inspection you’ll need to consult the manufacturer’s recommendations or your supervisor.

12. Daily Inspections A checklist that’s appropriate to your forklift can help guide you through a detailed inspection of the equipment.

13. Daily Inspections Begin with the forklift shut off, and include these parts in your inspection: The forks – are they spaced equally and are the blades free from cracks? Is the top clip retaining pin and heel in good condition? What’s the condition of the mast assembly? Do the hydraulic hoses and mast chains have any leaks, cracks or other visible defects?

14. Daily Inspections When checking this area, never place your hands inside the mast – to test the tension of the chains use a stick or other device. Look the tires over for excessive wear, and check for cuts and gouges in the rubber. Make sure the overhead guard isn’t bent, cracked or loose. If there’s a seatbelt, is it accessible and free of damage? Is the vehicle’s engine oil at the appropriate level?

15. Daily Inspections Depending on the manufacturer’s recommendation or your facility’s policy, you may also need to check other fluid levels as well.

16. Daily Inspections After this part of the inspection is over, start the forklift and continue with the inspection, including: The brakes – are they reliable, and do they stop the vehicle smoothly rather than in a sudden, gripping fashion that can cause tipping? Check that the head, tail and warning lights work and are aimed correctly.

17. Daily Inspections Test the horn. And make sure the gauges and instruments function properly. Check the steering wheel – is it responsive and free of excessive play? Are the control levers labeled? And do they move in a way that’s neither too loose nor too binding, returning to neutral when released?

18. Daily Inspections Your checklist will have additional parts to inspect. While it may seem like a lot to look over each day, it’s your life on the line and equipment that functions properly is critical to staying safe. If anything doesn’t pass inspection, note it on the paperwork and inform your supervisor. Any vehicle that’s defective, damaged or otherwise unsafe must be removed from service, until it can be repaired.

19. Maintaining Stability Because overturning is the number one cause of forklift related fatalities, it’s critical that you understand how to keep your vehicle stable and upright.

20. Maintaining Stability For forklift operators, a few important concepts can help them maintain critical stability. The first is known as the stability triangle. If we view a forklift from underneath, the stability triangle would extend from the two front wheels to the center of the rear axle.

21. Maintaining Stability We can visualize the vehicle’s center of gravity as a small circle – this circle moves about as the vehicle is used. For example, the center of gravity shifts forward when loading the forks, when raising the forks, or when braking. It shifts to the side when the forklift turns or if the mast is struck by falling objects. At all times, it should remain within the stability triangle – if the circle (or center of gravity) moves out of the triangle the vehicle will tip over.

22. Maintaining Stability What kinds of activities can cause this to happen? There are several: Starting or stopping too fast Slow, gradual starts and stops help keep your vehicle stable. Traveling with an elevated load Elevated loads are less stable, so travel with your load just high enough to clear the floor – typically about 4 inches off the ground.

23. Maintaining Stability Turning the forklift while traveling too fast Instead, make turns cautiously and at a reduced speed. Jerky movements while operating the hydraulic system. Again, easy, smooth movements are more stable.

24. Maintaining Stability Carrying a load that’s too heavy Just because the forks can lift a heavy load, don’t assume it’s safe to do so. A properly loaded forklift does not exceed the rated capacity of the vehicle – which can be found on the data plate that’s attached to the forklift.

25. Maintaining Stability Turning the forklift while traveling on a hill or incline. When traveling on a grade of 10 percent or more, always carry a load with forks pointing upgrade – that means when you go down a ramp with a load you’ll have to travel in reverse, so turn your head to look in the direction of travel. When traveling without a load, keep your forks pointing downgrade whether you’re moving up or down the ramp.

26. Maintaining Stability What should you do if your forklift does overturn? According to OSHA: “The procedure to follow in the event of tipover varies depending on the type of tipover and the class of forklifts that you may use in your facility.”

27. Maintaining Stability For tipovers on sit-down counterbalanced trucks follow these steps: Don’t jump. Stay in the forklift. Hold tight to the steering wheel. Brace your feet. Lean away from the impact. And, lean forward.

28. Maintaining Stability Finally, it’s important to emphasize that during a tipover seatbelts are nearly 100% effective at preventing fatalities. If your vehicle has a seatbelt, always buckle up before operating the equipment. For other types of forklifts, consult the operator’s manual or contact the manufacturer for the correct procedure to follow in the event of a Tipover.

29. Driving a Forklift When you’ll be operating a forklift, choose slip-resistant footwear and avoid loose clothing and dangling jewelry.

30. Driving a Forklift Before mounting the vehicle check your boots for grease and make sure your hands are dry so that they won’t slip.

31. Driving a Forklift When climbing on, face the forklift. Maintain three points of contact, with both hands and one foot, or both feet and one hand in contact with the forklift at all times, but avoid grasping the steering wheel - if it turns in your hand while you enter or exit it could throw you off balance.

32. Driving a Forklift Use the same care when exiting the forklift – never jump off the equipment. Once seated, if the forklift is equipped with a seatbelt, always fasten it. Before moving, make sure that the forklift has good clearance and look for pedestrians in the vicinity.

33. Driving a Forklift The appropriate height for the forks when traveling is about four to six inches at the tips, and two inches at the heels, which is low enough to provide stability, but high enough to clear most uneven surfaces and debris. Before starting out always look in all directions to make sure the way is clear of pedestrians and other traffic. Remember to make your stops and starts smooth and gradual, and keep your speed low enough that you can bring the forklift to a safe stop if something unexpected occurs.

34. Driving a Forklift While traveling keep your head, hands and feet inside the vehicle to avoid injuries from falling material or from protruding objects outside the cab. When crossing aisles or other locations where vision is obstructed, slow down and sound your horn. Be aware of other motorized traffic and maintain a safe distance of at least three truck lengths when following behind another forklift.

35. Driving a Forklift At intersections, blind spots or other dangerous locations, do not pass other forklifts traveling in the same direction. When turning, slow down to maintain balance, and turn the steering wheel in a smooth, sweeping motion.

36. Driving a Forklift As you move always look in the direction you’re traveling. If you’re carrying a large load that blocks your view, travel in reverse – remembering to turn and face the rear, sound your horn before moving, and travel slowly. While moving in reverse, avoid grabbing the overhead guard for support, as this could expose your fingers to a serious injury.

37. Driving a Forklift Remember that a forklift striking a pedestrian is the second most common cause of forklift-related fatalities, so give pedestrians plenty of room and stay alert for the unexpected, especially in aisles and doorways. Use your horn whenever you start out, or before entering an intersection, but never assume that pedestrians have heard you, especially in a noisy work environment.

38. Driving a Forklift Always give pedestrians the right-of-way, and never drive up to anyone who is in front of a bench, wall or any other fixed object – a brake failure or pushing a wrong lever could pin them between the forklift and the object. And, of course, never allow a pedestrian to ride on your forklift unless it’s specifically designed to accommodate passengers.

39. Driving a Forklift Watch for hazards in the environment – slow down for wet and slippery floors and avoid running over debris. When going over railroad tracks, cross diagonally whenever possible. If you work on a dock, avoid driving along the edge of the dock. Before driving onto a semi-trailer, verify that the driver has set the brake and chocked the wheels. Also make sure that the dockboard or bridgeplates are properly secured and that you’re load is within their rated capacity.

40. Driving a Forklift Finally, check that the floorboards are in good condition and will support the combined weight of the forklift, the load, and you.

41. Driving a Forklift When parking your forklift, choose an authorized location that won’t block traffic. If you’ll be moving more than 25 feet away from the forklift, or to a location where you can’t see it, the equipment is considered to be unattended. If this is the case, before exiting the forklift lower the forks to the ground, set the controls to neutral, set the brakes and turn off the power.

42. Driving a Forklift If you’ll be dismounting the equipment but staying within sight and within 25 feet, you must at least lower the forks to the ground, set the controls to neutral and set the brakes.

43. Driving a Forklift Depending on its power source, you may be required to either refuel your vehicle, or recharge it by plugging in or changing out the battery.

44. Driving a Forklift When performing any of these procedures always follow your facility’s safety policies, including wearing the appropriate Personal Protective Equipment, and knowing the location of the nearest eyewash stations and fire extinguishers.

45. Handling Loads Before handling any load, you must know the capacity rating for your forklift – in other words, how much weight the vehicle can carry. This can be found on the lift capacity plate attached to the vehicle.

46. Handling Loads It’s important to realize that, for this number to be accurate, you must stay within the vehicle’s load center. The load center is the distance from the vertical face of the forks to the load’s center of gravity.

47. Handling Loads The standard pallet in inches measures 48 by 48, and the center of gravity of a well-balanced load would normally fall at the 24 inch mark. For this reason many forklifts are designed with a load center rating of 24 inches.

48. Handling Loads When that’s the case, a full capacity load can be safely lifted to the maximum height of the forklift (as long as the load is kept vertical). As the load center increases (moves farther out from the forklift) the amount of weight that can be safely lifted decreases.

49. Handling Loads For this reason, many data plates list three lifting capacities based on different load centers. If you have questions about the safety of a load, talk to your supervisor before making the lift.

50. Handling Loads Before picking up a load, spread your forks as far apart as possible for greater stability. Depending on the forklift this can be done manually or with a hydraulic fork positioner. Approach slowly and “square up” on the center of the load with the forks in the low-to-the- ground traveling position.