Train the Trainer: Forklift Safety

Editor's Notes

• #4: This training will cover primarily standard forklifts – similar to one in the photo on this slide.
• #5: First thing – It is against the law for anyone under 18 to operate a forklift. This is both a state and federal law.
• #6: Because the cause of so many forklift accidents is lack of proper training, this training is required by L & I regulations for any person who will using a forklift.
• #7: Because the cause of so many forklift accidents is lack of proper training, this training is required by L & I regulations for any person who will using a forklift.
• #8: Forklifts are sometimes called powered industrial trucks or PITs. The most common type of PIT in use are the forklifts shown in the photos in this slide. Specialized PITs are used in warehouses, waterfront piers, logging and construction. The next few slides will describe the seven types of forklifts.
• #9: These battery-operated electric forklifts are typically used in warehouses where lack of ventilation makes the use of propane, diesel or gasoline powered forklifts, a carbon monoxide hazard.
• #10: These specialized electric forklifts are used primarily in warehouses with high stacks of stored goods.
• #11: These electric vehicles are sometimes called walkie-riders and are typically used in warehouses.
• #12: This propane-powered forklift is one the most common types of forklifts in use.
• #13: This is another common type of forklift often used outdoors.
• #14: These specialty PITs will not be covered in this training.
• #15: These heavy duty vehicles will not be covered specifically, but most of the information in this course would apply to them as well.
• #16: Sometimes these examples are confused with PITs since they can be used to perform similar tasks.
• #17: While the average automobile weighs around 3,000 pounds, the average forklift weighs around 9,000 pounds. Also, forklifts are heavier in the rear to counter the weight of items being carried in the forks. And, while cars have brakes on all four wheels, most forklifts only have stopping power in their front drive wheels. For that reason, forklifts are harder to stop, so they should be driven slowly.
• #18: This photo show the parts of a standard forklift. Other types will vary. All use hydraulic fluid to operate the forks. Most have a large counterweight in the rear to help balance a load on the front. Most have an overhead guard to protect the operator from falling objects. The main lifting work of the forklift is done with the forks and the mast, powered by the motor. Sometimes, older forklifts will develop a leak of hydraulic fluid. Without sufficient hydraulic fluid the forks will not operate properly, especially with a load. And a puddle of hydraulic fluid on a cement floor is a slipping hazard.
• #19: The nameplate gives important information about the capacity of the forklift. These must be readable at all times so any one who operates the forklift will know it's capacity and to not overload it.
• #20: If several people will be using the same forklift, or there is frequent changes in forklift operators over time, keeping the operation manual on the forklift is really important.
• #21: The stability of a forklift is important when you are handling heavy loads. The stability triangle is a way of describing how to keep the forklift stable and prevent it from tipping over with a heavy load. The next slide illustrates this idea further.
• #22: As the load is raised up and away, the center of gravity also shifts up and away from middle of the forklift.  If it moves outside the triangle formed by the front wheels and the center of the rear axle, the forklift will tip forward or fall to the side.  
• #23: A forklift with a raised load tends to be very unstable, especially with a load near the forklift’s lifting capacity. So as soon as the load is picked off the upper shelf in this photo, the load should be lowered before traveling or moving forward or backward.
• #24: As you can see from these illustrations, the center of gravity of the load should be as close to the forklift wheels and mast as possible.
• #25: In addition to the points on this slide, you should not pick up a load with just the tip or front part of the forks. Place the forks all the way under the load and then tip it back slightly. You may need to tilt the forks forward slightly to get under the load and later to deposit the load. But at all other times the forks need to be tilted back.
• #26: When you drive on an incline with a load, always have the load on the uphill side. L & I rules requires these procedures be followed if the incline is 10% or more. In addition, its especially important to tilt the load backward and keep it low. Raise the forks just enough to clear the surface.
• #27: Forklifts can turn over for all the reasons shown on this slide.
• #28: In the case of a tipover, whatever you do – don't jump. Hold on and lean away from the direction of the fall. You may be shook up and banged up a bit, but you will survive.
• #29: Forklift fatalities have occurred when the operator was either thrown out of the forklift or they tried to jump out when the forklift overturned. Seat belts prevent that. The video clip in the following slide is from Worksafe B.C. – the safety and health agency in British Columbia, Canada and covers the consequences of jumping from a forklift that is tipping over.
• #30: If your company has no assigned person to do forklift inspection and maintenance, the responsibility is yours. You should double check even if the company has maintenance personnel. If you operate a propane powered forklift indoors, check for noticeable propane or exhaust odors which mean an engine tuneup is required to keep carbon monoxide levels low. More about that in the slides following.
• #31: Propane is safe to use as long as it is contained. However, as this slide indicates, a large leak is a major hazard that could result in a fireball with severe burns to you or nearby workers. Some companies may have a propane cylinder exchange system where a propane vendor supplies full cylinders in exchange for empty ones. If you switch out empty cylinders with full ones, just remember to make sure all valves on the cylinders are closed.
• #32: If you have to change or charge batteries on your electric forklift, you could be exposed to the hazards of burns from battery acid or fire from hydrogen gas. Because of their weight, batteries are typically lifted with a hydraulic hoist. If you are the one that has to do that, be sure you know how to operate the hoist correctly.
• #33: Using an unapproved attachment can alter the forklift's lifting and balance characteristics and lead to the forklift overturning. The forklift must be marked in some way to show the weight of the attachment. This is usually found on the nameplate, unless it has been altered by a user without consulting the manufacturer. Doing so is actually a violation of forklift safety regulations.
• #34: Pallet loads are often shrink-wrapped or otherwise secured with strapping or other devices, especially in warehouses. But sometimes one-time or short-term jobs or other work conditions make that impossible. In those cases, proper stacking on a pallet is important. In addition, damaged pallets are subject to collapsing suddenly and the load being dumped or dropped.
• #35: Lifting someone on the forks of forklift is an extremely risky operation and often done “just for a minute” to accomplish some quick task. Don't allow yourself to be talked into it or think you can get away with it. Some employers may even fire you on the spot for doing this!! When a work platform is used, the forklift operator must always be in attendance – no further than 25 feet away, with the brake set. If the platform needs to be moved more than a few inches, the worker on the platform must get off first. No driving along with workers in the platform.
• #36: Order picker forklifts used in warehouses where the worker stands on the platform that raises and lowers presents a fall hazard. Workers who use this type of equipment must be protected by either a guard rail or the appropriate fall protection harness as shown. Waist-only harnesses, also called “body belts”, are not acceptable unless they completely prevent the operator from falling off the order-picker.
• #37: This is an example of what can happen if a safety harness is not available or used.
• #38: Mast configuration can affect the operator's visibility. Newer mast designs use two side cylinders with a gap in the middle which provide much improved visibility compared to older mast designs that have a single central cylinder. But with a tall load, your forward view will be blocked, making it necessary to travel in reverse or use a spotter.
• #39: When moving forward, the mast will block part of your view, even when the load is lowered.
• #40: Your employer may have restricted lanes for other workers – pedestrians – but people don’t always pay attention. You are often moving faster than a pedestrian and forklifts can’t stop suddenly, especially with a load. 10% of all fatalities involving forklifts are from workers being struck or run-over by a forklift. Don’t let it be your fault.
• #41: In this example of a real accident, the pedestrian walked behind the forklift without catching the attention of forklift operator even though the back-up alarm was sounding. The forklift operator failed to look backwards, so the forklift hit the pedestrian, knocked him down and badly injuring his leg.
• #42: Driving in and out of a trailer or railcar can cause either the ramp or the trailer itself to move. Securing truck trailer wheels prevents trailer movement and keeps dockboard secure. Dockboards or bridgeplates have various methods or attachments to keep them secure.
• #43: Wide loads are susceptible to shifting or sliding off the forks and of course make it difficult to maneuver in tight places. Irregular size loads can shift the center of gravity in unexpected ways. Caution in handling these types of loads is necessary. It is often safer to move a wide heavy load with a crane rather than a forklift.
• #44: In warehouses with high storage racks, the lightest loads should be placed on the top racks, and the heavier loads on the bottom racks. Remember a forklift is less stable with a load raised high, especially while moving.
• #45: The link to the Yale forklift company poster at the bottom of the slide is a good list of forklift safety practices. It can be simply viewed or printed out.
• #46: This example shows one reason why riders on a forklift is dangerous. The other reason would be that the rider could easily slip off the forklift since he has no seatbelt and is not sitting in a seat.
• #47: This is another example of an actual accident. The safer way this operator should have handled this situation was to slowly lower the load to the ground, set the brake and then dismounted the forklift and re-adjusted the boxes.
• #48: It goes without saying – just like any other moving vehicle, watch your speed. It's especially dangerous in a workplace with nearby workers and walls, doors, racks or stored material that block your view. As mentioned before, it's harder to stop a heavy forklift with a load than a car, even at low speeds.
• #49: Not leaving an operating forklift unattended is another requirement of the L & I safety regulations on forklifts.
• #50: You may have heard or been told that propane powered forklifts “burn clean” or don’t emit carbon monoxide. Although the amount is much less than a gasoline engine, they still do produce carbon monoxide and the levels can be quite high on poorly tuned forklifts. In fact carbon monoxide poisoning from indoor forklift operations is a common occurrence in Washington state, especially in the fall or winter when warehouse doors are closed up or ventilation is turned off or malfunctions. Symptoms of carbon monoxide poisoning are typically a severe headache, nausea or even collapse in worst cases. As you might expect, carbon monoxide poisoning is an even greater hazard with gasoline powered forklifts and diesel powered forklifts as well, in confined or unventilated areas.
• #51: Your training is not complete with this online course. This is just the beginning to give you some general information on forklifts, how they work and the hazard associated with operating them. You also need supervised hands-on training with the specific forklift you will be using. This is required by L & I regulations as well as making common sense. An 8 question quiz follows this slide. You get two tries on each question and a passing score is 75% or 6 or more correct answers. You do not need a special printed certificate to operate a forklift, just the appropriate training.