P1246990959dcvzy

1
Forklift Operator Safety
2
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

3
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

4
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.

5
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

6
Forklift Fatalities

• What age group has the highest number of
• fatalities?
• 18 24
• 25 34
• 35 44
• 45 54

7
Fatalities by Age Group
8
Regulatory Requirements

• According to 29 CFR 1910.178
• Operator must receive training before operating a
  forklift
• Demonstrate competency
• Forklift characteristics
• Operating environment
• Inspection and maintenance

9
Forklift Basics
www.Lni.wa.gov
Image Credit State of WA-WISHA Services
10
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
• 2 - 3 times the weight of a car

Image Credit State of WA-WISHA Services
11
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
12
Determine a Loads 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 items center of gravity
  and load center

Image Credit State of WA-WISHA Services
13
Stability Triangle

• Stable forklift without a load
• Stable forklift with maximum load
• Unstable forklift with offset maximum load

14
Combined Actions

• Center of gravity (COG) side to side
• COG forward
• COG backward
• Combination of two can cause tip-over

15
Vertical Stability
16
Attachments Approved OSHA Safety Cage

• Change operating clearances
• Change capacity
• Change stability and load center

Image Credit State of WA-WISHA Services
17
Operating Hazards Pedestrians

• Forklift accidents involving pedestrians may be
  caused by
• Obstructed view
• Turning
• Speeding
• Pedestrian unaware forklift is present
• Carrying passengers and horseplay

18
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

19
Operating HazardsLoad Carrying

• Load-carrying hazards include
• Working around loading docks
• Loads that block the forward vision
• Stacking and un-stacking on racks

20
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.

21
Forklift Characteristics and HazardsAny
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?

22
Conduct a Preoperational Inspection

• Conduct a preoperational inspection
• Follow the inspection checklist
• Complete and sign the checklist

23
Inspection Walk-around

• Check that the forklift is properly
  disengagedforks down, key off, neutral gear,
  parking brake on
• Check left and right sidetires, lug nuts, axle,
  overhead guard, and no debris behind the mast
• Check frontforks, hoses, fork pins, backrest,
  mast, and chains
• Check rearcounterbalance and radiator

24
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

25
While in the Operator Seat

• Make nonmoving checksgauges, lights, horn,
  backup alarm, warning light, tilt and lift
  mechanism, and parking brake
• Make moving checksseat belt, running brakes, and
  steering
• Look for oil or water leaks on the floor

26
Operating a Forklift

• Authorized operators only
• Quickly report accidents
• Always wear seat belts
• No person under the forks
• Operate controls only from drivers seat
• Never block exits or emergency equipment

27
Tip-Over Safety Procedure

• Always wear your seat belt
• Hold onto thesteering wheel
• Brace your feet
• Lean away fromthe fall

Image Credit State of WA-WISHA Services
28
Loading and Unloading

• Never over-load the forklift
• Check the weight of the load
• Locate the loads center of gravity
• Inspect the load (stability)
• Restack unstable loads
• Tow from the rear towing pin

www.lni.wa.gov/Safety
Image Credit State of WA-WISHA Services
29
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

30
Traveling

• Look in the direction of travel
• Keep body inside cage
• Keep forks low when traveling
• Sound the horn
• Dont speed
• Check clearance
• Keep the load tilted back slightly

Image Credit State of WA-WISHA Services
31
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

32
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

33
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

34
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

35
Parking

• Dont block exits oraisles
• Lower the forks
• Set gear to neutral
• Set the parking brake
• Turn off the key

36
Whats Wrong Here?

• Identify the hazards

37
Whats Wrong Here?
38
Whats Wrong Here?
39
Whats Wrong Here?
40
Whats Wrong Here?
41
Propane Refueling

• Highly flammable gasdo not smoke
• Report leaks immediately
• Distinct odor
• Hissing sound
• Frost on fittings
• Use gloves and safety glasses
• Have fire extinguisher nearby

42
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

43
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 corrosivewear PPE
• Have fire extinguisher nearby

44
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

45
Carbon Monoxide Poisoning

• Internal combustion engines produce carbon
  monoxide. This gas can rapidly build up in
  anyindoor 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.

46
Inspection, Operation, and MaintenanceQuestions?

• Any questions about inspection procedures?
• Any questions about operating procedures?
• Any questions about vehicle maintenance?

47
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

48
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

49
References

• www.osha.gov
• www.ini.wa.gov/safety/defualt.asp
• BLR