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 Counter-balanced trucks Cantilevered trucks Rider trucks Forklift trucks High lift platform trucks Low lift trucks Low lift platform trucks Motorized hand trucks Pallet trucks (electric) Narrow aisle rider trucks Straddle trucks Reach rider trucks Single side loader rider trucks High lift order picker rider trucks Motorized hand/rider trucks Rough terrain trucks

Forklift Fatalities What age group has the highest number of fatalities? A) 18 – 24 B) 25 – 34 C) 35 – 44 D) 45 – 54

Fatalities by Age Group

Regulatory Requirements According to 29 CFR :  Operator must receive training before operating a forklift  Demonstrate competency Forklift characteristics Operating environment Inspection and maintenance

Forklift Basics 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  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 load center Image 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 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

Image Credit: State of WA-WISHA Services Attachments – Approved OSHA Safety Cage  Change operating clearances  Change capacity  Change stability and load center

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

Driver Distraction

Operating Hazards—Load Carrying Load-carrying hazards include:  Working around loading docks  Loads that block the forward vision  Stacking and un- stacking on racks

Operating Hazards— Pedestrians Forklift accidents involving pedestrians may be caused by:  Obstructed view  Turning  Speeding  Pedestrian unaware forklift is present  Carrying passengers and horseplay

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 but stay nearby you must at least follow steps 1, 2 & 4.

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 Inspection  Conduct a 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 equipment

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)  Restack unstable loads  Tow from the rear towing pin Image Credit: State of WA-WISHA Services

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 Check behind, to both sides and above prior to moving

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?

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. **Always close the valve at the end of the day

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 changes in personality and memory. Once inhaled, carbon monoxide decreases the ability of the blood to carry oxygen to the brain and other vital organs. Even low levels of carbon monoxide can set off chest pains and heart attacks in people with coronary artery disease.

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:  wheels are out of alignment  the forks lift unevenly

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 BLR