1. Forklift Safety

2. Disclaimer
The information presented in this presentation has been compiled from sources believed to be reliable and is intended to be a tool to assist and guide you in building your own presentation. This program may not address all the hazardous conditions or unsafe acts that may exist. For that reason, SPIN cautions users to confirm accuracy and compliance with the latest standards and best practices. Local, State/Provincial and Federal regulations take precedence over this material. Implementation of any practices suggested by this program is at your sole discretion, and SPIN will have no liability to any party for any damages including, but not limited to, direct, indirect, special or consequential damages, arising out of or in connection with the information provided or its use.

3. Forklift Safety Training
Safe operating procedures of a forklift
The pre-operation inspection checklist
Safe loading and unloading of trailer
Safe fueling procedures
Written Evaluation
Operator performance test
Retraining
Learning Objectives:
3 Understand how a forklift works.
3 Perform a forklift inspection using the inspection checklist.
3 Be able to safely operate a forklift.
3 Understand safe fueling procedures.
3 Pass an operator’s skills test with at least a score of 80%.
This means that you can’t miss more than 5 questions.
3 Be retrained every two years.
Insert Videotape:
3 Length is 15 minutes.
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4. Most Common Accidents Person or object struck by forklift.
Material falls on bystander or operator.
Operator is injured getting on or off equipment.
Forklift tips over because the rated load capacity is exceeded, or the load is handled improperly.
Approximately 34,000 injuries a year.
Note:
3 Over 37,000 forklift-related injuries occur in the U. S. each year, and many of these injuries result in fatalities.
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5. Safe Operating Procedures
Employee’s must be trained and authorized before operating a forklift.
Know all safety devices and functions.
Mount and dismount correctly
Perform pre-operational inspection
Never operate a forklift in need of repair
Never operate a forklift for any purpose other than what it was designed for
The General Safety Rules for Safe Operating Procedures:
3 All employee’s must be trained and authorized before they are allowed to operate a forklift.
3 Know all safety devices and functions (ie.) back up alarm,
horn.
3 Mount and dismount using 3 point’s of contact at all times.
3 Pre-operation inspection must be performed before the start of each shift by a trained and authorized employee.
3 Never operate a forklift in need of repair. It should be tagged out of service until repairs have been made.
3 Never operate a forklift for any purpose other than what it was designed for.
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6. Keep hands and steering free of slippery material.
Operate the forklift only from the operator’s position.
Always travel at safe speeds.
Never allow any other person to ride on the forks or anywhere else.
A safety platform is the only exception, because it is designed for a passenger.
The General Safety Rules for Safe Operating Procedures Cont.:
3 Keep hands and steering free of all slippery material.
3 Operate the forklift only from the operator’s position.
3 Always travel at safe speeds. Keep in mind, the safe speed may vary depending on the load.
3 Under no circumstance allow any other person to ride on the forks or anywhere else.
3 A safety platform is the only exception, because it is designed for a passenger.
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7. Fueling Procedures No smoking or use of open flames
Shut off the forklift before fueling
Avoid breathing the fumes
Be sure you are using the proper fuel (Taxable Diesel)
Avoid overfilling the tank
Clean up any spills before starting the unit
Replace the fuel cap
Watch for leaking fuel lines
Wear eye protection and other protective gear
Fueling Procedures:
3 Not only is diesel combustible, but it is also a possible carcinogen. (cancer causing agent)
3 Be sure you are using the proper fuel (Taxable Diesel)
3 Wear eye protection and other protective gear as necessary.
Note:
The equipment that we are using here at the shop facility is diesel, however there is also Electrical and Liquid Petroleum.
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8. Pre-Operational Checklist
All forklifts will be inspected before each shift of operation.
If repairs are needed, it will be tagged “Out of Service” until repairs are completed.
A work order will be completed identifying repair needs.
Pre-Operational Checklist:
3 Will only be performed by trained and authorized employees.
3 Will be completed by the first person to operate the forklift.
3 Failure to complete the pre-operational checklist may result in a written reprimand, termination or both.
Note:
3 Any deficiency, should be noted on a work order and reported to the Shop Foreman immediately. It should also be tagged “Out of Service” until repairs have been made.
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9. Pre-Operational Inspection
BASIC FORKLIFT PRINCIPLES
Pre- inspection checklist:
When inspecting a forklift, look for the following items:
3 Cracked Welds 3 Low fluids
3 Corroded battery components 3 Leaking hydraulics
3 Worn or cracked tires 3 Loose wheel nuts
3 Broken gauges or mirrors 3 Damaged lights, horn or b/u alarm
3 Worn parts 3 Bent overhead guard
3 Proper operation of steering wheel and control levers
3 Damaged mast, forks or carriage
Note:
Reinforce that:
3 Any deficiency, should be noted on a work order and reported to the Shop Foreman immediately. It should also be tagged “Out of Service” until repairs have been made.
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10. Pre-Operational Inspection
MAST
ROLLER TRACKS AND CHAINS
FORKS AND ADJUSTMENT
FLUID LEVELS
HYDRAULIC LINES
LIFT AND TILT CYLINDERS
OVERHEAD GUARD MOUNTING
FIRE EXTINGUISHER
CYLINDER MOUNTING HARDWARE
TIRES
LIGHTS AND WARNING DEVICES
HANDBRAKE
STEERING AND BRAKES
DRIVING CONTROLS
LIFT CONTROLS
SEAT ADJUSTMENT AND BELTS
Inspection Procedure:
1. The inspection will be completed daily prior to its use, by the first person to operate the forklift.
2. The inspection tag will be fully completed and signed by the person conducting the inspection.
3. Any deficiencies will be noted on the inspection tag, the Shop Foreman will be informed of all deficiencies and the forklift will be tagged “Out of Service” until corrections have been made.
4. After being tagged “Out of Service”, a work order form will be filled out listing all deficiencies.
5. Once repairs are completed the forklift will be given a performance test to ensure the equipment is safe to operate.
6. The work order will then be signed by the person completing the repairs, and it will be maintained on file by the Shop Foreman for the life of the equipment.
Notes:
3 Do a sample with class.
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11. Leaving a Forklift Unattended
Fully lower forks
Neutralize controls
Set brakes
Turn off the motor and remove the key
If parked on an incline, block the wheels
Never park in front of emergency exits
Unattended Forklift:
3 When a forklift is left unattended, the equipment will be put into neutral, the emergency brake will be set, and the power will be shut off. When the forklift is parked on an incline, the emergency brake will be set.
3 The forklift will be considered unattended when the operator is 25 feet or more away, or when the vehicle is not in operator’s view.
3 Before the operator has dismounted the forklift, the load will be lowered, controls will be neutralized, and the brakes will be set.
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12. Picking up loads Never exceed the rated capacity of your unit
Forks must be spaced properly
Be sure the load is stacked properly and is balanced
Secure the load to the pallet
Drive into load as far as possible
Tilt the load back slightly & then lift it
Watch for overhead objects or side objects
Lower load 4 to 6 inches above ground level for travelling
Note:
3 Make sure no one is standing near the load.
3 If another load is in front of the one you are picking up, lift the load without tilting it. Back out about a foot, then tilt the mast back to avoid catching or hooking the material in front of the load being lifted.
3 Always look in the direction the forklift is moving.
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13. Picking Up Round Objects:
3 To pick up round objects, forks should be tilted and not used flat.
Notes:
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14. Lifting Principle INCORRECT CORRECT 6500lbs REAL HEAVY PARTS
LOAD CAPACITY
6000 lbs
PROPANE ONLY
6500lbs
REAL HEAVY PARTS
INCORRECT
CORRECT

15. TYPES OF FORKS FORK ADJUSTMENT HALF-TAPERED FORKS
- USED WITH HEAVIER LOADS
FULL-TAPERED FORKS
- USED WITH LIGHTER LOADS
- USED WITH NARROW PALLETS
TYPES OF FORKS
FORK ADJUSTMENT
FORKS SHOULD BE SPREAD AS
WIDE AS POSSIBLE TO ALLOW FOR
MAXIMUM STABILITY OF THE LOAD!
Spreading of Forks:
3 With the forks spread wide, the load is well distributed and tends to bind itself together.
3 By placing the forks to close together, the load can become unstable and off balance.
Notes:
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16. Traveling with loads Pedestrians have the right-of-way
Look in the direction of travel
Forks should be 4 to 6 inches above ground level if terrain permits
Mast should be angled slightly back
Slow down and sound horn when approaching blind corners
Drive in reverse if your forward vision is obstructed
Traveling with Loads:
3 Never raise the load while traveling regardless of speed.
3 Always slow down when turning, with or without a load.
Note:
3 When thinking of blind corners remind everyone how crowded the yard can get, and to take extra care with all the parked vehicles. (especially on Fridays)
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17. Do not lift or lower a load while travelling
Go down an incline in reverse and up an incline going forward
Turning to fast can cause a load to shift or fall
Starts and stops should be gradual
Never let anyone ride on your forklift
Be aware of slippery surfaces, bumps or holes
Safe following distances (at least 3 vehicle lengths)
Keep limbs inside compartment
Seat belts must be worn at times while in operation
Traveling with Loads Cont.:
3 Keeping your arms and legs inside the forklift may prevent cuts, scrapes, snagged clothing and amputation.
Note:
3 If the forklift is equipped with seatbelts they must be worn the entire time while operating the forklift.
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18. Trailer Operations
ENSURE THE TRAILER FLOOR IS RATED FOR THE VEHICLE WEIGHT
VERIFY THAT THE TRAILER FLOOR IS IN SERVICEABLE CONDITION
ENSURE THE FORKLIFT WILL NOT UNBALANCE THE TRAILER
USE ADDITIONAL TRAILER SUPPORTS IF UNBALANCING IS A RISK
CONSIDER THE INTERIOR TRAILER HEIGHT
ENSURE THE TRAILER CANNOT ROLL AWAY FROM THE DOCK
CONSIDER LIGHTING AND INCLEMENT WEATHER

19. Stacking & Dropping Loads
Never stand under a load that is raised
Always move slowly when the load is raised
When stacking insure that the load is level and secure
Stack round objects tightly together and place chock or block
Be careful when backing out of a load where a pedestrian is in your pathway
Stacking and Dropping Loads:
3 Always ensure that the material in the stack will not be crushed by the load.
3 Make sure that no one is standing near the load.
Note:
3 The same principles apply to both stacking and dropping a load.
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20. Lift Classifications & Rated Load Capacity
The maximum amount of weight that can be safely lifted.
The rated capacity of a forklift can be found on the identification plate on the forklift, or in the manufacturer’s Operator’s Manual.
To test the load’s weight, the operator should: Lift the load one or two inches Make sure it is firm and stable
Lift Classifications and Rated Load Capacity:
3 Class-D Diesel powered has few safeguard against fire hazards. This should be kept in mind when operating the forklift.
3 Also, a Diesel powered forklift releases carbon monoxide in the exhaust. Use caution in areas that may not be well ventilated.
3 Here at the shop facility, the two forklifts are Class D.
Note:
3 Operator must know were to find the rated capacity, and understand what it means.
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21. Lift Classifications and Rated Load Capacity:
3 Class-D Diesel Powered (We are currently using Class-D)
3 Class-DS
3 Class-DY
3 Class-E
3 Class-ES
3 Class-EE
3 Class-EX
3 Class-G
Note:
3 It is the operator’s responsibility to know how much the load weighs. If uncertain, the operator should talk to the supervisor.
If there are no questions at this time issue out test and explain.
Have twenty minutes to complete, and can not miss more than 5. (At least %)
Employee must also complete the skills test before being considered a qualified operator. Announce the time that the skills test will be offered.

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