FORKLIFT SAFETY

Joint and Health Safety Committee

Training Objectives
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

Why Forklift Training

Is Necessary
100 fatalities each year
20,000 lost workday injuries
annually
Common injuries

Hitting a pedestrian
Tipping over
Improperly positioned loads
Falling from raised forks
Falling from a ladder struck with a
forklift
Falling material

Forklift Operation
OSHA 1910.178 states Only
trained and authorized operators
shall be permitted to operate a
powered industrial truck.

Types of Forklifts

Different types of forklifts are

available, mainly for different
environments:
Diesel powered
Electric powered

Interesting Facts
Forklifts weigh thousands of
pounds (4,000 - 8,000 lbs.)
Are extremely powerful.
Use rear wheel steering.
Can turn in a very tight circle.
Are not very wide for use in
aisles.

Truck Body

Overhead Guard

Hydraulic Lift

Gauges

Truck Controls

Switches

Data Plates

OSHA requires a
legible nameplate
It includes
information about
the forklift and
attachments
It lists the maximum
load capacity
It describes the load
center

Rear Wheel Steering

Unlike a car or truck, lift trucks

use the rear wheels for

Load Capacity

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 load on the

side closest to its
center of gravity

CENTER OF
180LB
GRAVITY OF LOAD

TOP VIEW OF LIFT TRUCK

300LB

CENTER OF GRAVITY
LOAD CENTER

Stability Triangle
Vehicle Center of
Gravity (unloaded)
Stability Triangle

Center of Gravity of
Vehicle and Maximum
Load (Theoretical)

Stability Triangle
The

closer the center of gravity (CG) is to line BC

the more stable the forklift is
The closer the CG is to lines AB or AC the more
unstable the forklift becomes
If the CG ever goes outside the stability triangle,
the forklift can tip

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Loads too heavy or offset

Taking corner too fast
Traveling surface is not level

What Can Cause a Tipover?

Center of gravity
side to side

Center of gravity
forward

Center of gravity
backward

Combination of actions or
circumstances can cause tipover

Tipover Safety Procedure

Always wear your

seat belt

Hold onto the

steering wheel

Brace your feet

Lean away from

the fall

Illustration credit: Rolls High Reach

Load Centering

Load Centering

Load Centering

Speed
KEEP YOUR
SPEED DOWN!
Maintain indoor
speed under 5 mph (8 km/hr)
outdoor speed under 15 mph
(24 km/hr).

Conduct a
Preoperational
Inspection

Forklift is
properly
disengaged
Walk to both
sides
Check front
Walk to rear

The safety equipment you must

inspect daily is:

Diesel-powered
Check

all oil and fluid levels

Check cables
Check fan belt, fan, and radiator
Check tank, and hose attachments
Electric-powered
Check

the battery condition

While in the Operator Seat

Make nonmoving checks

gauges, lights, horn, backup
alarm, warning light, tilt-andlift mechanism, and parking
brake

Make moving checksseat

belt, running
brakes, and steering

Look for oil or water

leaks on the floor

Operating a Forklift

Handling and Moving Loads

Picking

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up load

Approach the load straight on with the forks in the

travel position
Stop when the fork tips are approx. 1 foot away from
the load
Level forks and drive slowly forward until load is
against backrest
Lift the load high enough to clear what is under it

Handling and Moving Loads

Picking

up load (cont.)

Look over both shoulders to make sure you

are clear and slowly back out one foot
Sound

horn before backing if cant clearly see

behind you

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Slowly tilt mast back to stabilize the load

Handling and Moving Loads

Setting

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down the load

Drive to location, square up to load area

and stop about one foot away
Level the forks and slowly drive forward
Lower the load
Tilt the forks slightly forward
Look over your shoulders and back
straight out until the forks clear the load

Stacking and Unstacking

Lifting

32

a load

Approach the load slowly with the forks in

the travel position
Stop approx. one foot away from the load
and raise forks to correct height
Level forks and drive forward until load is
flush against backrest

Stacking and Unstacking

Lifting

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a load (Cont.)

Lift high enough to clear the bottom load,

look over both shoulders to see if clear to
back and slowly back straight out
After clearing top of stack, stop and lower
mast to travel position
Tilt forks back
Proceed to destination

Stacking and Unstacking

Stacking

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a load

Approach placement area slowly and square

Stop about one foot away and lift mast high
enough to clear the placement area
Move forward slowly until the load is square
over the stack
Level the forks and lower the mast until the
load is resting on the stack
Slowly back straight out

Stacking and Unstacking

Additional

Never lift a load while moving

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tips

Stop completely before raising the mast

Make sure the top load is squarely stacked

on bottom load
Always approach and leave the load area
slowly
Always look over shoulders before backing
up

Driving with a Load

Travel

with load tilted slightly back for stability

Travel with the load at the proper height
4-6

Inches at fork tips

2 Inches at heels
Drive

in control
Drive in reverse if you cannot see over the load

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Driving on Inclines - Ramp/Slope

Always

drive with the heavier or less stable

end of the forklift pointing up the incline

If the forklift is loaded (heavier/less stable in front)

Drive

forward up the incline with the load

Drive in reverse coming down the incline with the load
pointed up the incline

If the forklift is not loaded (heavier in rear)

Drive

forward down the ramp

Drive in reverse going up the ramp

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Stopped Forklift
When

Parked or unattended

Forks flat on ground

Turn off engine
Set parking brake
Do not block:
Exits
Emergency

equipment
Signs or postings
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Pedestrians
Pedestrians

have the right of way

Slow down at intersections

Look before backing
Use horn when coming around blind corners and
at blind intersections
Check mirrors at intersections if they are present
in workplace

Pedestrians

must be cautious in areas where

forklifts may be operating

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Attachments such as pallets

Change operating
clearances

Change capacity

Change stability
and load center
Image Credit: CDC

Operating Hazards Pedestrians

Accidents

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

Operating Hazards
Environmental Conditions

Combustible fueloperated forklift in

poorly ventilated area

Traveling on ramps

Crossing railroad tracks

Slippery floors

Operating on dirt
or gravel

Poor lighting

Operating Hazards
Load Carrying

Working around
loading docks

Loads that block

the forward vision

Stacking and
unstacking on
racks

Whats Wrong Here?

Forks not fully lowered

Forklift parked on
sloped surface

Refueling and Recharging

Park in designated refueling or
recharging area.
Do not block emergency equipment.
Make sure area is well ventilated.
Have extinguisher nearby.

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Refueling and Recharging

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Turn off engine and lights.

Do not smoke.
Do not spill fuel.
Use only approved cans.
For LP, shut off valves.
When charging, remember
gases.

Test your Knowledge

1. The first step toward safe
forklift operation is to conduct
a preoperational
_____________ inspection
_________.
2. Your inspection should continue
operators
when you are in the _________
seat
____.
authorized ______
drivers
3. Only __________
should operate a forklift.
4. If you are in a tipover, never
jump
try to ____.
5. When traveling in a forklift,
keep the forks low
___.

WORD BANK
preoperational inspection
battery test
operators seat
warehouse
authorized drivers
supervisors
jump
remain seated
low
high

Inspection, Operation, and

MaintenanceQuestions?

Inspection procedures?

Operating procedures?

Vehicle maintenance?

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