Risk Management Department Forklift 1
Introduction to Forklift Operating a forklift is an important job. So important that the federal government requires that all lift truck operators be trained and authorized by their organizations. OSHA regulation CFR1910.178 states: "Only trained and authorized operators shall be permitted to operate a powered industrial truck." 2
Introduction to Forklift This training - together with the training provided by your supervisor on the specific operation of the forklifts you will be authorized to use will give you the knowledge to operate a forklift in a safe, professional manner. 3
Introduction to Forklift During this training, you will learn about: Hazards of forklift operation Forklift accident statistics Safe forklift operation 4
Forklift Hazards Forklifts can be dangerous to untrained persons because they operate differently than other vehicles such as cars and trucks. Forklifts: Often weigh more than a car Have reduced visibility Often use rear-wheel steering Operate in a more complex traffic environment Can ride less smoothly due to tire types Are more sensitive to shifts in center of gravity 5
Forklift Hazards There are two general categories of hazards associated with forklift operations: Hazards of the forklift itself Hazards of the environment 6
Forklift Hazards Hazards of operating a forklift: Load capacity Lift Height Load stability Visibility Steering Speed Turning Refueling Maintenance 7
Forklift Hazards Hazards of the environment: Floors/Surfaces Pedestrians Obstacles Blind spots Narrow aisles Intersections Docks & trailers 8
Forklift Hazards Not to mention hazards of the thought process! 9
Accident Statistics Every year, there are 680,400 accidents involving forklifts in the United States Of these, there are 90,000 injuries! 10
Accident Statistics These accidents break down as follows: Tip-overs: 25.3% Hit by forklift: 18.8% Hit by falling load: 14.4% Use of lift as elevator: 12.2% Lift falls off dock: 7% Improper maintenance: 6.1% 11
Accident Statistics Forklift overturned: 24% Struck by falling loads: 17% Struck by other truck: 14% Fall from forklift: 14% Crushed by forklift: 11% Ran off loading dock: 8% Worker making repairs on forklift: 6% 12
There are several areas to consider to ensure safe forklift operations. These are: 1. Stability and center of gravity 2. Load capacity 3. Driving 4. Parking 5. Inspection 6. Refueling 13
1. Stability and Center of Gravity Support points A, B & C form the stability triangle Center of gravity is the point at which load is concentrated If center of gravity remains inside the triangle, the truck won t tip 14
2. Load Capacity Check data plate Don t exceed maximum: Load capacity Load center Lift height Changing the load center changes the load capacity 15
2. Load Capacity Place heaviest load against back of forks Ensure loads are neatly stacked, stable, evenly distributed and secure Place forks under the load as far as possible Adjust forks to widest possible setting Tilt forks back for added stability 16
3. Driving Match speed to load and conditions Decrease speed at all corners and sound horn Watch for pedestrians and obey posted traffic signs 17
3. Driving Safe driving Keep forks as low as possible; don t drive with load raised Position forks to tilt back slightly If view is blocked, travel in reverse Watch for overhead obstructions 18
3. Driving No Passengers No lifting people Use your seat belt Keep hands and feet inside of truck No standing under forks when raised If following, maintain 3 length distance No passing at intersections 19
3. Driving Be aware of: oil spots, wet spots, loose object or holes Avoid if possible: ice, mud, gravel, sand and soft dirt Make sure area you are driving over can support the weight of the truck and the load 20
3. Driving Ramps & Inclines If empty: Drive in reverse up the incline Drive forward down the incline If loaded: Drive forward up the incline Drive in reverse down the incline 21
3. Driving Loading Docks & Trailers Be aware of the edges of loading docks Set brakes on trucks/trailers and choke wheels Inspect interiors Ensure that dock plate & interior surfaces can support weight Watch clearance 22
4. Parking Set forks flat on floor Place controls in neutral Shut off engines Set brakes Block wheels if on an incline Do not block emergency areas 23
5. Inspection pre- and post-trip: Hydraulics Uprights Forks Attachments Leaks Tires/wheels 24
5. Inspection pre- and post-trip: Brakes Steering Controls Lights & signals Engine 25
5. Inspection pre- and post-trip: Horn Fluid levels Battery Hour meter Report problems to your supervisor! 26
6. Refueling Park in designated recharging/refueling area Ensure adequate ventilation Don t smoke No open flames, sparks, or electric arcs nearby Have fire extinguisher nearby Use proper personal protective equipment Always check lines, wires, hoses for leaks 27
6. Refueling Recharging Electric Trucks Wear splash proof goggles and protective clothing Check electrolyte level before charging Keep tools and metallic objects away from battery top Do not pour water into acid Watch for spilled materials Ensure battery is secure 28
6. Refueling Gasoline or Diesel Trucks Turn off ignition and lights Make contact between spout and fill pipe before pouring Check for leaks Clean up any spills Make sure you use an approved container 29
6. Refueling Gasoline or Diesel Trucks Shut valve; let engine run until it stalls Turn off ignition and lights Check for leaks and damage to connections Wear protective clothing Remove empty tank and store it Install new tank securely 30
You are finished! You have finished the Forklift training. Download the quiz from the link on the Risk Management Department website training page. Print the form and be sure to write your name, location and employee number in the spaces provided. Complete the ten questions and have your supervisor send it to the Risk Management office. 31