Forklift Operation

Forklift Accidents Forklifts cause about 85 fatal accidents per year. 34,900 accidents result in serious injury and 61,800 are classified as non-serious. There are about 855,900 forklifts in the U.S. There for over 11% of all forklifts will be involved in some type of accident each year

What Caused Them? Crushed by tipping over 42% Crushed between lift and surface 25% Crushed between two lifts 11% Struck or run over by lift 10% Struck by falling load 8% Fall from platform 4%

Forklift Class IV - Internal combustion engine trucks with cushion Tires. These forklifts are used inside on smooth dry floors for transporting palletized loads to and from the loading dock and the storage area. The cushion tired forklifts are lower to the ground than pneumatic tired forklift truck. This allows cushion tired forklift trucks more useful in low clearance applications.

Rough Terrain Forklift Rough terrain forklift is a generic term used to describe forklifts typically intended for use on unimproved natural terrain and disturbed terrain construction sites. However, the term “rough terrain” does not imply that the forklift can be safely operated on every conceivable type of terrain. Rough terrain forklift has a boom that extends and raises. Some rough terrain forklift have outriggers at the front, which allows the forklift to be stabilized on uneven grounds.

Forklift Incidents March 18th at 8:45 am Rain for Rent employee was operating a forklift to move a pump into the shop.  As he was backing the forklift he backed into the side of a parked RfR F550 #1007, causing appx $3000 damage to F550, no damage for forklift.  He was not using a spotter.   His vision was blocked by hood of rain gear.   Training records do not indicate employee was forklift certified.

OSHA Required Training OSHA rules dictate that forklift operators be certified and trained in forklift safety. OSHA requires that the training be: A combination of classroom and hands-on Retraining done every three years An evaluation of an operators driving skills

OSHA Required Training Refresher training must be provided when the following occurs: The operator has been involved in an accident or near-miss. The operator has been assigned to a different type of truck. A condition in the workplace that changes the safe operation of a truck. The operator has been observed handling the truck in an unsafe manner.

Authorized Operator Only trained and authorized personnel are permitted to operate a forklift Keep unauthorized employees off of forklifts Keep pedestrians away from the operating zone of a forklift Lock out unsafe lifts as determined in a preoperation inspection I. Background for the Trainer: OSHA clearly states that only trained and authorized personnel are permitted to operate a forklift. II. Speaker’s Notes: Authorized operators have the authority and the responsibility to prevent unauthorized operators from even getting on a forklift. The untrained individual can easily hurt or kill someone or damage the facility. Keep pedestrians safely away from the forklift when moving, lifting, etc. If the forklift is found to be unsafe during a preoperation inspection, the authorized driver has the responsibility to lock it out until it is repaired.

Forklift Incidents Rain for Rent employee witnessed this incident. Other employee got stuck in the mud with the boom too high up. Tried to cross a ditch and tipped over. Employee tried to jump out and out his in the head by the boom, forced to the ground.

Authorized Operator Forklift operators need to be aware of their surroundings at all times. They need to be aware of any sudden drop offs, hills, potholes, walls, or anything else in the area. It is vital that forklift operators avoid these obstructions in order to safely transport their cargo. Both bystanders and forklift drivers need to stay out of each other’s ways, as a collision could be catastrophic.

What is your Responsibility? You are responsible for your safety and the safety of others around you as the operator You are responsible to communicate to your supervisor and or co-workers when you don’t feel comfortable with the forklift you are operating, Job site conditions, lack of information for task at hand. You are responsible for the safety of others working around or near the forklift.

Forklift Incidents December 20th Rain for Rent employee drove the forklift into the wash bay.  As he was backing out of the bay, the mast hit and damaged 3 panels of the partially lowered overhead door.   While employee was in the wash bay, a co worker started to lower the door, then realized the forklift operator would need to come out, leaving the door partially lowered. Employee is forklift certified.

Autos V.S Forklifts What is the difference? Weight A 5,000 Lb forklift weighs between 9,000 and 12,000 Lbs. The largest SUV weighs only up to 7,000 Lbs. Weight affects Braking and Braking Distances. Autos have 4 wheel braking, forklifts have 2 wheel braking

Auto V.S Forklift Steering Autos have front wheel steering Forklifts have rear wheel steering Rear wheel steering causes the rear end to swing out wide when turning

Five Steps to Safe Operations 1. Walk Around 2. Functions Test 3. Work Place Inspection 4. Safe Operation 5. Safe Shut Down

Step One - Walk Around Visual inspection of the forklift. A visual inspection is to be done while the forklift is off. Use a forklift inspection checklist. Don't forget to check for operators manual.

Step Two - Function Test Check all functions the unit is capable of performing. Check hydraulic functions, forward, reverse, steering, horn, back up alarm and braking system. Complete the function test found in the operators manual. Look for oil or water leaks on the floor

Step Two - Function Test (cont) Nonmoving checks Gauges, lights, horn, back-up alarm, blinking warning light, operate the tilt and lift mechanism, check the parking brake Moving checks Put on the seat belt, check the running brakes, check the steering Check hydraulic functions, forward, reverse, steering, horn, back up alarm and braking system. I. Background for the Trainer: After presenting this slide, it would be a good time to take the employees out of the class to demonstrate the forklift preoperation inspection. Have a couple of the employees also do the inspection so that everyone gets an opportunity to see it done more than once. II. Speaker’s Notes: When checking the tilt, listen for unusual sounds. When checking the lift mechanism, inspect the hoses and chains and listen for unusual sounds. Check the parking brake by putting the forklift in gear (both forward and reverse) and stepping on the accelerator. The forklift should not move. Check the running brakes by moving forward and backward at a high speed and slamming on the brakes. The lift trucks should quickly stop. Inspect the steering by doing full turns to the right and left; listen for unusual sounds.

OHSA Fatal Facts Two laborers and a fork lift driver were staking 40-foot-long I-beams in preparation for structural steel erection. One laborer was placing a 2 X 4 inch wooden spacer on the last  I-beam on the stack. The fork lift driver drove up to the stack with another I-beam that was not secured or blocked on the fork lift tines. The I-beam fell from the tines, pining the laborer between the fallen I beam and the stack of beams.

Step Three - Work Place Inspection Check ground surfaces Check for overhead obstructions. Check for debris Check for other work being done.

Step Four - Safe Operation Only trained, authorized operators Only use the lift with in its intended limits. ALLWAYS Obey all safety rules and regulations. Continuously scan for hazards and changing conditions Pedestrians always have the right-of-way When turning, watch rear end swing

Forklift Accidents Rain for Rent employee one week on the job. No experience driving forklift.

Safe Operation (cont) Never lift or transport people on the forks of the truck. Check clearance under overhead installations Do not operate an unsafe unit. Seat belts must always be worn Smoking is not permitted Never carry passengers

Safe Operation (cont) Immediately report forklift-related accidents No person should stand under elevated portion of lift truck Forklift controls operated only from driver’s seat Never block exits or emergency equipment If a unit appears to be defective or not properly functioning report to your supervisor immediately. I. Background for the Trainer: The information on this slide is generic and may not apply to your facility. Feel free to change the bullet points so that they coincide with the general operating rules of your company. These and additional rules should be spelled out in your Powered Industrial Truck Program. What is your company’s policy concerning using a forklift as a man lift? In some states, this is illegal. Discuss this issue with the employees if using a forklift as a man lift is permitted by your state and your company. Note that discussing “rules of the road” can put employees to sleep if you just read the rules point for point. Create interaction by asking questions such as What’s so important about wearing seat belts? They just slow me down when I climb in and out of the forklift. What’s wrong with standing under the elevated portion of a lift truck? II. Speaker’s Notes: For the next few slides, we will discuss the rules of the road. These are also outlined in your copy of the Powered Industrial Truck Program. Standing under elevated forks may be deadly if the hydraulic system fails.

Safe Operation (cont) 3 point contact mounting and dismounting Always look in the direction of travel Keep body inside the cage Sound the horn at intersections and backing Operate at safe speeds No stunt driving or horseplay

OHSA Fatal Facts Employee was operating an aerial lift, with an extendable boom rotating aerial work platform. He was thrown from the basket while moving the machine. The boom was fully extended and the machine apparently ran over some bricks, causing the boom to flex or spring, throwing the employee from the basket. The fall was about 37 feet to a concrete surface. The employee died from severe head and chest injuries.

Step Five - Safe Shut Down Park unit out of the way of other traffic Take unit out of gear Set Parking brake Lower and tilt forks forward Deny access to those who are not authorized to operate the lift. (Remove the key) Place cones in front and rear of lift.

Propane Refueling Propane is a combustible, compressed gas Propane leaks are detected by: Distinct odor Hissing sound Frost on fittings PPE: gloves, safety glasses and face shield Use only with adequate ventilation. Keep away from heat, sparks and flame. Avoid contact with eyes, skin and clothing. Do not breathe vapor or mist. Keep container closed. I. Background for the Trainer: What is your company’s policy regarding propane refueling? Are all operators permitted to fill propane cylinders, or is refueling limited to specially trained personnel? It is important to physically demonstrate how to refuel or replace propane tanks. Refer to the forklift’s manual for specific refueling procedures. II. Speaker’s Notes: Do not smoke around propane. It is a highly combustible gas that can cause a fire or even explode if not handled correctly. Report propane leaks immediately. Leaks can be detected by the distinct odor, a hissing sound, or frost on the fittings. Minimum personal protective equipment (PPE) requirements for propane refueling are gloves and safety glasses. Additional PPE might be goggles or a face shield.

Battery Charging Inspect battery connectors for damage No smoking in battery-charging area Immediately clean up electrolyte spills PPE includes face mask, acid-resistant gloves, and an apron I. Background for the Trainer: Refer to the forklift’s manual for specific refueling procedures. Can all the operators change out or inspect batteries, or is this job limited to specially trained individuals? II. Speaker’s Notes: Hydrogen gas is released during the recharging process, so smoking in the area should be prohibited. Clean up electrolyte spills with baking soda (acid neutralizer) and water. Never remove battery caps except to add water or take hydrometer readings. Always wear PPE when working with batteries because you never know when the electrolyte might bubble or gas up.

Forklift Accidents October 4th  at 2:45 pm Rain for Rent employee was at customers jobsite (Orange County Water District) using RSC rental reachlift to remove a 40' X 8" pipe with stinger from a pond with boom extended and outriggers out to clear pumps.  As Errol lifted an outrigger to begin dragging pipe out of the lake, the lift tipped over on its side.   Employee is certified for all terrain forklift operation.

Forklift Attachments Check operators manual for proper attachments Functions test and capability's Restrictions and weight rating Specific operator training Weight of attachments Increased load center

Vehicle Capacity Only handle loads within truck’s rated capacity Capacity is found on nameplate

Nameplate The nameplate has a great deal of information to help you safety operate the forklift. OSHA requires a legible nameplate Includes modifications and attachments Capacity and Load center Tire size Fuel type Maximum lifting height I. Background for the Trainer: Inspect your forklifts to be sure that they all carry accurate legible nameplates. If the forklift has been modified or an attachment has been added, a new nameplate must be obtained from the manufacturer to reflect the changes to the capacity of the forklift. If possible, photocopy a nameplate from a forklift to show the employees how to find information on the nameplate. II. Speaker’s Notes: OSHA requires a nameplate that is specific to the lift truck and any attachments that are used. Report any forklift that does not have the proper nameplate. The nameplate contains a lot of information, such as weight of the forklift, tire size and pressure, fuel type, etc. However, the most important information to you is the capacity and load center. Capacity: The specific maximum weight of a load that can safely be lifted to the forklift’s maximum lifting height, assuming the center of gravity of the load is within the rated load center. Load center: The distance between the vertical face of the forks and the center of gravity of the load.

Stability Triangle Load CG Load CG Vertical Stability Line (Line of Action) Combined CG Combined CG Vertical Stability Line (Line of Action) Truck CG Truck CG This vehicle is unstable and will continue to tip over The vehicle is stable

Center of Gravity Balance point 48” A Distance from the edge of the item to the item’s center of gravity I. Background for the Trainer: The center of gravity is an important concept for all forklift operators to understand. Use blocks or Legos® to help demonstrate the location of a load’s center of gravity. II. Speaker’s Notes: Before we talk about capacity and load center, we need to discuss how to determine a load’s center of gravity. The center of gravity is the exact point on which the entire load will balance. For loads of consistent material, this point will always be near the center of the load. If a load contains materials with different weights or densities, the load center will be on the side containing the heavy material. For example: If a pallet contains bricks on one side and pillows on the other, the center of gravity will obviously be closer to the side of the pallet containing the bricks. The distance from the edge of the load to the center of gravity is very important. If possible, the load must always be picked up on the side that is closest to the center of gravity. This will keep the load’s weight closer to the forklift. The center of gravity of item A above is 24 inches from the edge. Would it be better to pick up item B from the left or right side? The left side, of course, because the center of gravity is closer to the left side. B 20” 40”

Combined Actions Center of gravity moves side to side Center of gravity moves forward I. Background for the Trainer: This slide is used to show operators how their actions could cause a forklift to tip over. Usually, a tip over does not result from one action but a combination of two or more actions. II. Speaker’s Notes: What causes the center of gravity of a lift truck to move from side to side? Forklift cornering, unbalanced load, tire going into a pothole, sloped surface What causes the center of gravity of a lift truck to move forward? Capacity load, mast tilted forward, stopping abruptly when going forward, quickly accelerating in reverse, driving down a ramp What causes the center of gravity of a lift truck to move backward to the thin portion of the stability triangle? Mast tilted back, stopping abruptly when going in reverse, quickly accelerating forward, driving up a ramp Which of the above actions, when combined, could cause a forklift to tip over? A forklift cornering while driving up a ramp would cause the center of gravity to be back and to the side, thus resulting in a tipover. A forklift moving forward with a raised capacity load could tip forward if forced to stop abruptly. A forklift cornering with an unbalanced load and then hitting a pothole could easily tip over. These are just a few examples of how a forklift can be tipped over. Center of gravity moves backward to the thin portion of the triangle

Straight Mast V.S Rough Terrain Straight mass has 3 main functions. Raise and lower Mass. Side shift Mass. Tilt Mass Forward and Back.

Forklift Accidents Rain for Rent employee flipped the forklift 2.5 times down a hill on a job site. Did not have rough terrain certification. Employee was not injured. Very lucky to be alive.

Straight Mast V.S Rough Terrain Rough Terrain Forklift has 4 main functions. Boom in and out Boom up or down Tilt mass forward or back Carriage Leveler Some Rough terrain forklifts have outriggers.

Rough Terrain Forklift Center Of Gravity With a rough terrain forklift the center of gravity will change as you use any of the 4 basic functions. The lifting capacities will change as you boom up, down, in and out. Know the weight of what you are picking prior to lifting. Estimate how far you will have to boom up, down, in or out.

Rough Terrain Forklift Center Of Gravity Telescoping forklifts have the capability of leveling the carriage. This function is used to help keep your load level. Level your load prior to moving the lift. If you are already in motion and you have to level the load, stop slowly and then level. Never level while in motion.

Slopes Always have the load facing the up hill part of the slope. Never approach a slope at an angle. Always go straight up and down. Use low gear so the engine brake can assist your braking capabilities.

Slopes (cont) Never turn while going up or down a slope. If you must turn make a wide slow turn. Turning to fast will cause your lift to loose its center of gravity resulting in a roll over. Never adjust your load while on a slope. Carry the load as low to the ground as possible.

Ramps and Railroads Never turn on a ramp On ramps the load should be upgrade Ascend or descend ramps slowly Railroad tracks are crossed diagonally I. Speaker’s Notes: Turning on a ramp is a good way to tip over. Keeping the load upgrade will keep the combined center of gravity in the center of the stability triangle. When not loaded, driving with the forks downgrade will keep the center of gravity toward the front or the wide part of the stability triangle. Crossing railroad tracks diagonally will help keep the lift truck stable. If you park within 8 feet of the center of railroad tracks, you may be hit by a train when it passes.

Working on Docks Inspect the dock plate Check the trailer floor condition Make sure trailer wheels are chocked Make sure nose of the trailer is supported by the tractor or a fixed jack I. Background for the Trainer: Does your company have proper dock plates, wheel chocks, and trailer supports? II. Speaker’s Notes: These four habits are crucial to safety when loading/unloading trailers with a lift truck: Check the dock plate for cracks or signs of wear, and be sure it is properly secured. Check the trailer floor for holes that the tire of a forklift could fall into, causing a tipover. Chock the trailer wheels to prevent trailer creep. Support the nose of the trailer.

Questions? Any Questions? For more information regarding hazards in the workplace, contact EHS&T at 661399-9128 Ext. 445.