Forklift Safety

1
Forklift Safety

• Only forklift operators may operate the forklift.
• In addition to written training, ALL forklift
  operators must receive and pass a live driver
  test to ensure comprehension of the written
  material

2
Forklift Safety

• PRE -QUALIFICATIONS FOR POWERED INDUSTRIAL TRUCK
  OPERATORS (PIT)
• All candidates for PIT operators must meet the
  following
• basic requirements prior to starting initial or
  annual training
• Must have no adverse vision problems that cannot
  be corrected by glasses or contacts
• No adverse hearing loss that cannot be corrected
  with hearing aids
• No physical impairments that would impair safe
  operation of the PIT
• No neurological disorders that affect balance or
  consciousness
• Must not be taking any medication that affects
  perception, vision, or physical abilities

3
Forklift Safety

• INSPECT THE FORKLIFT BEFORE EACH USE
• Do not use the forklift if any of the following
  conditions exist
• The mast has broken or has cracked weld-points.
• The roller tracks are not greased or the chains
  are not free to travel.
• The forks are unequally spaced or cracks exist
  along the blade or at the heels.
• Hydraulic fluid level is low.
• The hydraulic lines and fittings have excessive
  wear or are crimped.
• Fluid is leaking from the lift or the tilt
  cylinders.
• The hardware on the cylinders is loose.
• The tires are excessively worn or split,
• or have missing tire material.
• Air filled tires are not filled to the operating
• pressure indicated on the tire.
• The batteries have cracks or holes,
• uncapped cells, frayed cables, broken
• cable insulation, loose connections
• or clogged vent caps.

4
Forklift Safety

• CHANGING AND CHARGING STORAGE
• BATTERIES
• Only charge batteries in designated areas.
• Handle batteries using a conveyor, overhead
  hoist,
• or equivalent material handling equipment this
• is provided.
• Properly position and secure reinstalled
  batteries
• Use a carbon filter or siphon to handle
  electrolytes.
• When charging batteries, pour acid into water DO
  NOT pour water into acid.
• Properly positioned the truck and apply the brake
  before changing or charging batteries.
• Take care to assure that vent caps are
  functioning.
• Leave the battery (or compartment) cover/(s) open
  to dissipate heat.
• DO NOT SMOKE in the charging area.
• Prevent open flames, sparks, or electric arcs in
  battery charging areas.
• Tools and other metallic objects shall be kept
  away from the top of uncovered batteries.

5
Forklift Safety

• FUELING SAFETY
• Fuel tanks shall not be filled while
• the engine is running. Avoid spillage.
• Spillage of oil or fuel shall be carefully
• washed away or completely evaporated
• and the fuel tank cap replaced before restarting
  engine.
• No truck shall be operated with a leak in the
  fuel system until the leak has been corrected.
• Open flames shall not be used for checking
  electrolyte level in storage batteries or
  gasoline level in fuel tanks.

6
Forklift Safety

• Maintenance of Powered Industrial Trucks
• Remove trucks not in safe operating condition.
  Repairs to be made by authorized personnel.
• Repairs to fuel and ignition systems that involve
  fire hazards to be completed in designated areas.
  Replacement parts to comply with original truck
  specifications and design.

• Inspect daily, report defects immediately.
• If the temperature of any part of the truck is
  found to be in excess of its normal operating
  temperature, remove the vehicle from service.
• Keep Industrial trucks in a clean condition,
  free of lint, excess oil, and grease.
• Noncombustible agents should be used for
  cleaning trucks. Low flash point (below 100 deg.
  F.) solvents may not be used. High flash point
  (at or above 100 deg. F.) solvents may be used.

7
Forklift Safety

• SAFE OPERATION PROCEDURE FOR
• CHARGING LPG TANK
•  
• No Smoking.
• Move LPG PIT outside for refueling.
• Turn off PIT.
• LPG tanks will be removed in the following order
  
• shut off service valve
• disconnect tank from hose
• unbuckle and remove tank from bracket
• LPG tanks will be replaced in to following order
  
• place tank in bracket and re-buckle
• reconnect hose to tank and tighten firmly
• -open valve slowly and assure proper seal
• NOTE Federal Law Prohibits dispensing an
  improper fuel type into any Vehicle or into a
  non-approved fuel container.

8
Forklift Safety

• SAFE OPERATION PROCEDURE FOR CHARGING LPG
  TANK
• In Case of LPG Leaks or Tank Rupture
• DO NOT start or move the PIT.
• If fuel hose is leaking, Close valve immediately
  and
• place PIT "Out of Service" until repaired.
• If tank ruptures, warn others, immediately leave
  the area (at least 50 feet) and notify
  Management. Do not re-enter the area until
  cleared by Management.

OUT OF SERVICE
9
Forklift Safety

• TO START THE FORKLIFT
• Apply the foot brake
• and shift gears to neutral
• before turning the key

10
Forklift Safety

• PICKING UP A LOAD
• Approach straight on with forks in travel
  position
• Stop when tips about 1 foot from load
• Level forks, drive forward until load rests
  against the backrest of the mast

• Lift the load high enough to clear anything
  underneath
• Back up 1 foot, slowly and evenly tilt the mast
  backwards to stabilize

• PUTTING DOWN A LOAD
• Square up and stop 1 foot from desired
  location
• Level the forks, drive to the loading spot
• Slowly lower the load to the floor, tilting
  forks slightly forward
• Back straight out until forks have cleared the
  pallet
• STACKING ONE LOAD ON TOP OF ANOTHER
• Use the same approach as above

11
Forklift Safety

• FORK LIFT SAFETY RULES
• Do not use bare forks as a man-lift platform
• Approach railroad tracks at a 45 angle when
  driving the forklift
• Steer the forklift wide when making turns
• Sound the forklift horn to warn your approach
• LIFTING
• Do not exceed the lift capacity of the forklift
• Follow the manufacturer's guidelines concerning
  changes in the lift capacity
• Lift the load an inch or two to test for
  stability
• If the rear wheels are not in firm contact with
  the floor, take a lighter load or use a forklift
  that has a higher lift capacity
• Wait until you are in the loading area and have
  stopped before raising or lowering the load
• Raise the forks an additional two inches to avoid
  hitting or scraping the ramp surface as you
  approach the ramp

12
Forklift Safety

• DRIVING
• Obey all traffic rules and signs
• Drive with the load at a ground clearance height
  of 4-6 inches at the tips and 2 inches at the
  heels in order to clear most uneven surfaces and
  debris
• Drive at a walking pace
• Do not drive into an area with a ceiling height
  that is lower than the height of the mast or
  overhead guard
• Do not drive along the edge of an unguarded
  elevated surface
• Do not exceed a safe working speed of five miles
  per hour.
• Stay a minimum distance of three truck lengths
  from other operating mobile equipment

13
Forklift Safety

• Drive in reverse and use a signal person when
  your vision is blocked by the load
• Look in the direction that you are driving
  proceed when you have a clear path
• Do not drive the forklift while people are on the
  attached man-lift platform
• Drive unloaded forklifts in reverse when going up
  a ramp and forward when going down a ramp
• Drive a loaded forklift in a forward gear when
  going up a ramp upon approaching the ramp, raise
  the forks an additional two inches to avoid
  hitting or scraping the ramp surface
• Do not attempt to turn the forklift around on a
  ramp
• Do not use a gear for the opposite direction of
  travel as a means to slow down or stop the
  forklift
• Lower the mast completely, turn the engine off
  and set the parking brake before leaving your
  forklift

14
Forklift Safety

• TRAVELING
• All traffic regulations shall be observed,
  maintain a safe distance from the truck ahead.
• Yield to ambulances, fire trucks,
• or other vehicles in emergency
• situations.
• Do not pass other trucks.
• Slow down and sound the horn at
• cross aisles and other locations
• where vision is obstructed.
• Cross railroad tracks diagonally wherever
  possible. Park no closer than 8 feet from the
  center of railroad tracks.

15
Forklift Safety

• Look in the direction of, and keep a clear view
  of the path of travel.
• Grades shall be ascended or descended slowly.
• Operated the truck at a speed that will permit
  stopping in a safe manner.
• Stunt driving and horseplay is not be permitted.
• Slow down on wet and slippery floors.
• Secured dock-board or bridge-plates before they
  are driven over.
• Avoid running over loose objects on the roadway
  surface.
• When turning reduced speed to a safe level by
  turning the hand steering wheel in a smooth,
  sweeping motion.

16
Forklift Safety

• LOADING DOCKS
• Keep the forklift clear of the dock edge when
  backing up to the dock
• Only start loading or unloading when the supply
  truck has come to a complete stop, the engine has
  been turned off, the dock lock has been engaged
  and the wheels have been chocked
• Do not drive the forklift into the truck until
  the bridge or dock plate has been attached
• Do not drive the forklift into a truck bed or
  onto
• a trailer that has "soft" or loose decking or
• other unstable flooring
• Drive straight across the bridge plates when
• entering or exiting the trailer
• Use dock lights or headlights when working in a
• dark trailer

17
Forklift Safety

• TRUCKS AND RAILROAD CARS
• Check for breaks and weakness before driving
• onto trucks, trailers, and railroad cars
• The brakes of highway trucks shall be set and
• wheel chocks placed under the rear wheels to
• prevent the trucks from rolling while they are
• boarded with powered industrial trucks.
• Wheel stops or other recognized positive
• protection shall be provided to prevent railroad
• cars from moving during loading or unloading
• operations.
• Use a fixed jack if necessary to prevent a
  semi-trailer
• from upending.
• Ensure that railroad cars will not move while
• dock-boards or bridge plates are in position.