Safe Operation of Forklifts

and other powered industrial trucks (PITs)

May, 2011
 Safe Operation of Forklifts
and Other Powered Industrial Trucks
The following topics will be covered:

• Forklift-related fatalities
and injuries
• Types of forklifts
• How a forklift operates
• Hazards of forklift
operation
• How to use forklifts safely Wikimedia commons
 Safe Operation of Forklifts
and Other Powered Industrial Trucks

You must be 18 years or older to operate a forklift

 Safe Operation of Forklifts
and Other Powered Industrial Trucks

The risk of ignoring forklift safety

Forklifts are extremely useful in a

Source: WorksafeBC
variety of
workplaces, but there is great risk of
property damage, injury or death if you:

• Are not trained on forklift safety

• Are not familiar with the specific

Source: RiteHite Doors

forklift vehicle
• Operate the forklift in an unsafe
manner
• Operate a forklift with a defect or
missing parts
 Safe Operation of Forklifts
and Other Powered Industrial Trucks
85 to 100 workers in the U.S. are killed every year in forklift accidents.
Forklift accident statistics Approximately 35,000 serious injuries
and 62,000 non-serious injuries
Fatal Accident Type % involving forklifts occur in the United
Crushed by vehicle States every year. OSHA estimates
42% 11% of all forklifts are involved in
tipping over
Crushed between accidents every year.
25%
vehicle and a surface
Crushed between two

Source: Monash University – Australia

11%
vehicles
Struck or run over by a
10%
forklift

Struck by falling material 8%

Fall from platform on the

4%
forks

View Fatality examples

 Safe Operation of Forklifts
and Other Powered Industrial Trucks
Washington State forklift accidents & citations
The 5 most common citations by L & I safety inspectors
involving forklifts in last three years (2007 – 2009) were
as follows:
1. Lack of training
2. No seatbelt or not using seatbelt
3. No inspection of the forklift for defects
4. Modification of forklift without manufacturer’s
approval
5. No nameplate or unreadable nameplate

13 employees were killed in forklift-related accidents from 2000 to 2009

1000+ employees were seriously injured (had to take time off from work to
recover) in forklift-related accidents in the years 2006, 2007 & 2008
 What is a powered industrial truck (P.I.T.)?
Definition: A powered vehicle used to carry, push, pull, lift,
stack or tier materials.

Another way of describing powered

industrial trucks is that they include
standard forklifts and special use
forklifts and industrial vehicles.

They are all regulated by the DOSH

P.I.T. regulations – WAC 296 - 863

The Industrial Truck Association list seven classes of PITs:

Class 1 Electric Truck Class 5 Truck
Class 2 Electric Truck Class 6 Industrial Tractor Truck
Class 3 Hand Truck Class 7 Rough Terrain Truck
Class 4 Truck
 Types of Forklifts
Class 1 Electric Truck
Has the following:
1. Electric motor
2. A counter-weight in the rear
3. Solid or pneumatic (air filled) tires
4. Operator sits and drives

The "mast“ is the

telescoping track on
which the forks and
Counter-weight and battery.
load are raised and
lowered.

Forks on a forklift. Some trucks

have a solid platform and are
called "platform trucks”.

Solid tires for smooth surfaces.

Pneumatic tires are used for
rougher surfaces.
 Types of Forklifts
Class 2 Electric Truck
Characteristics:

1. Electric motor
2. Narrow construction to fit in aisles
3. Solid tires

On some models, forks reach in

and out as well as up, down and tilt.
Other models have the forks on the
side (called "Side Loaders“ ) or
allow the forks to pivot to the side
(called "Front/Side Loaders”).

The operator stands on a platform Straddle legs add stability

which moves up and down. for forklifts that don't use a
Sometimes called an “order picker” counter-weight
 Types of Forklifts
Class 3 Hand Truck
Electric Motor Hand or Hand/Rider Trucks

Characteristics:
1. Motorized
2. Walk behind or ride
3. Low or high lift
4. Counter-weight or straddle

This motorized pallet jack has

a counter-weight. Straddle
legs are provided on more
compact or reach models.

The operator can walk behind or stand on

the platform and hold onto the grab bar.
 Types of Forklifts

Class 4 Truck
Characteristics:
1. Propane internal combustion
engine
2. Solid tires
3. One of the most common types

Propane/liquid petroleum gas (LPG)

fuel cylinder. Other forklifts run on
diesel or gasoline.
 Types of Forklifts

Class 5 Truck

Characteristics:

1. Gasoline, diesel or propane

engines
2. Pneumatic tires
3. Used outdoors in many
cases.

Pneumatic (air filled) tires with tread are used for

traction and stability on rough or wet surfaces.
 Types of Forklifts
Class 6 Industrial Tractor Truck
Characteristics:
1. Electric or internal combustion

Wikimedia Commons
engine
2. Solid or pneumatic tires
3. Specialty vehicles
Yard Tractor
4. Pull or carry loads (no forks)
Wikimedia Commons

Wikimedia Commons
Industrial Tractor Straddle carrier
 Types of Forklifts
Class 7 Rough Terrain Truck
Characteristics:
1. Used outdoors in uneven or
muddy locations
2. Pneumatic tires
Log Yard Forklift
3. Gasoline or diesel-powered

Rough Terrain Reach Forklift Rough Terrain Mast Forklift

Types of Forklifts

Ship Container PITs

Wikimedia Commons
 Types of Forklifts
These are not powered industrial trucks (forklifts).

Farm vehicles Self-propelled elevated

Non-powered pallet jack work platform

Bobcat skid steer with forks

Earth-moving vehicle All photos – Wikimedia Commons
 How is a forklift different from a car or truck?
• Usually steers from the rear, rather than the front, making
it swing wide
• Carries heavy loads, often in tight places and rough terrain
• Can have reduced visibility
• Can have a high center of gravity making it susceptible to
turnover
• Controls are different and more complicated
• Heavier than most cars and trucks

This….. …..doesn’t operate like these.

Parts of a Forklifts

Wikimedia commons
 Forklift Nameplate

The nameplate will list the type of forklift and the capacity

Weight

Type
Load
capacity
OSHA

This forklift is a propane (LP) powered forklift, weighing 8680

lbs. with a lifting capacity of up to 4500 lbs.
 Forklift Operating Manual
Since there are numerous makes, models and types of
forklifts, it is important to check for warnings in the specific
forklift operator’s manual.

The manual should be kept on the forklift at all times.

 Forklift Stability Triangle

Almost all counterbalanced powered industrial trucks supported at three

points. This is true even if the vehicle has four wheels. The truck's steer axle is
attached to the truck by a pivot pin in the axle's center. When this point is
connected to the front wheels with imaginary lines, this three-point support
forms a triangle called the stability triangle. So long as the center of gravity
remains within this stability triangle, the truck is stable and will not tip over.
 How loads affect forklifts

A forklift balances a load with a counterweight at the back.

The front wheels act as a fulcrum or balance point. The
center of gravity moves upward when the forks are raised.
Don’t travel with a raised load!
 Forklift Load Capacity

Right Wrong

While carrying a load near the maximum allowable

capacity, be aware of the following:
 Danger of tip over
 Danger of losing load
 Danger of being struck by falling load
 Moving the load

Use extra caution when handling loads that approach the

truck's maximum rated capacity:
 Tiltthe mast & forks back and position the heaviest part of
the load against the carriage.
 Travel with the mast tilted back to keep the load stable.
Never travel with the load tilted forward. Tilting the load
forward increases the load distance and makes the load
less stable.
 Driving on an incline
Always drive with the load on the uphill side - go backwards
driving down the incline and frontwards going up the incline to
prevent tipping or losing control of the forklift.

If no load on the forklifts, do the opposite with forks

pointing down the ramp.
 More reasons why forklifts tip over

 Driving too fast around a

corner

 Driving off edge of platform,

ramp, road or other surface

 Driving an indoor forklift Source: RiteHite Doors

outdoors on rough, uneven

ground outdoors

 Operating on an incline or hill

 What do in case of a forklift tip-over

If the forklift tips, keep your arms and legs inside and hold on to
the steering wheel. Don’t attempt to jump out – you can’t move
faster than the forklift can tip over. Most people who attempt to
jump are killed by the impact of the overhead guard.
Tipover procedures for other types of forklifts may vary. For example operators of
stand-up forklifts with rear-entry access should step backwards off the forklift if a
tipover occurs.
 Forklifts and Seatbelts
Seatbelts are required on all forklifts manufactured
since 1992 and can be retrofitted on all older models.

You are required to uses it when it is supplied with the

forklift. It will save your life.
Click it - before you drive!!

worksafeVictoria
A common cause of forklift fatalities is from the
operator not having or using a seatbelt.
Forklift video clips from Worksafe B.C.

1. STAY IN THE CAB, STAY ALIVE

2. FIELDS OF VISION: PEDESTRIAN

SAFETY AROUND FORKLIFTS
 Forklift inspection and maintenance
All forklifts be examined at least daily before being used.
Forklifts used on a round-the-clock basis must be examined
after each shift. Check the following:
 Fluid levels -- oil, water, and hydraulic fluid.
 Leaks, cracks or other visible defect in hydraulic
hoses and mast chains.
 Tire pressure and tire cuts or gouges.
 Condition of the forks, including the top clip
retaining pin. U.S. Army

 Safety decals and nameplates in place and

legible.
 All safety devices working properly including the
seat belt.
A vehicle that is damaged, defective or otherwise
unsafe must be removed from service. Report the MSHA

problem to your supervisor immediately.

•

Refueling a propane powered forklift

Liquid propane is extremely cold when
released to the atmosphere. If your skin is
exposed to propane while refueling, you
can get frostbite.
Shut off the engine before refueling.
Don’t leave propane-powered forklifts near
high heat sources. When parking
propane-powered forklifts for a long period
of time, turn the tank valve off.
Any propane leak must be taken seriously.
Propane vapor is heavier than air and will
tend to sink to the lowest lying area. If not
adequately dissipated, it will ignite when
exposed to a spark or flame.
 Charging or changing batteries on
electric forklifts
The battery changing/charging area
should have the following:
 No smoking signs.
 Adequate fire protection.
 Plenty of water for flushing and
neutralizing spilled battery acid.
 An eyewash that provides at least
15 minutes of flowing water
enough ventilation to remove
hydrogen gas during battery
charging.
If you have to add water to batteries or handle battery acid, be sure to wear
personal protective equipment.
 Forklift Attachments

Forklifts can have a variety of

attachments which affect their
performance and use.
Crane Attachment
The load capacity of the forklift is
reduced by the weight of the
attachment.
Drum Grabber Attachment
The attachment must be approved
by the forklift manufacturer.

Be sure you know how to use the specific

attachment on the forklift you will be operating or
get training if you don’t.
Carpet Lifting Attachment
 Stacking loads on pallets

IRREGULAR STACKING PATTERNS

Wood strips, plywood or heavy cardboard
BLOCK BRICK PINWHEEL
between layers can help stabilize castings,
The most common. Containers are Used where brick pattern is
bags, and other irregular shapes.
The upper level may be interlocked by unstable.
unstable if not encircled turning each level
with wire or strapping. 90 degrees.

Loose loads are subject to falling. Off center loads can also
be subject to falling or cause the forklift to tip over. The
illustrations above show the correct way to load pallets.

Avoid using damaged pallets.

 Forklift Work Platforms

Never lift other workers on forks unless you use an

approved work platform with railings as shown.

Source: Pelsue Co.

U.S. Army

Dangerous!! Safe
An extremely dangerous practice
A risky way to change a light bulb!!

Source: JICOSH
 Order Picker Fall Protection
In warehouses “order picker” forklifts, the vehicle must
have either:

• Standard guardrails on all open sides

or
• A safety harness and lanyard

CDC
OSHA
 Why a safety harness is needed on an
order picker forklift

While working in a warehouse using

an order picking forklift, a worker tried
to stand on a shelf to adjust the
position of the load on the pallet. His
foot slipped from the rack and he fell

Source: JICOSH
from the fourth tier to the floor.

A safety harness would

Source: JICOSH

have stopped his fall.

 Forklifts have reduced visibility
Both the forklift mast and a large load on the forks
reduce forward visibility.

Older mast design Newer mast design

In warehouses or other indoor workplaces, aisles of material, walls,

doors and other building configurations can create blind corners.
OSHA – all photos
Forklift Blind Spot

Blind spot
 Forklifts and Pedestrians
• Slow down and sound horn at
intersections, corners, and wherever
your vision is obstructed.

• When provided, use flashing warning

light or backup alarms when traveling in
reverse.
• Always look in the direction of travel.
• Signal to pedestrians to stand clear.

OSHA
• Do not allow anyone to stand or walk
under upraised forks.

• When possible, make eye contact with

pedestrians or other forklift operators
before moving in their path.
 Forklift-pedestrian accident example

Source - JICOSH

Source - JICOSH

Neither the pedestrian or the forklift operator were paying attention!!

 Loading truck trailers and railroad cars
Make sure:

• Truck trailer wheels are chocked

• Dock board is secure and can

handle weight
OSHA
• You use horn or warning lights
when exiting trailer or railcar.

OSHA
 Wide or irregular size loads

Source - New York Dept. of Health

OSHA

Distribute the weight evenly when carrying irregular sized loads.

Keep the center of gravity of the load as near as possible to the
center going horizontally across the forks.
Keep the center of gravity of the load as near to the front wheels
as possible.
Loading/unloading High Storage Racks
When removing a load from a high rack:
• Slowly back out with the load
• Stop when it clears the rack
• Lower the load to the floor
• Don’t lower the load while moving!
 Forklift Do’s and Don'ts
No one else on the forklift except
the operator, unless the forklift
has a seat for a rider.

Source: JICOSH
Always drive with the forks
lowered and lower forks to floor
when parking the forklift.

Watch overhead clearances –

especially entering or exiting
buildings or when you are raising
Source: JICOSH

a load on the forks.

Click here for Yale forklift company safety poster

 The risk to a rider on a forklift

A seasoned forklift operator sat

next to the operator's seat while
showing a new operator how to
operate the forklift.

Source: JICOSH

The new operator accidentally

performed the wrong maneuver,
causing the forklift to run into one
of the pillars at the site. The worker
who had been training him was
crushed between the support pillar
and the forklift. Source: JICOSH
 Stay out of the mast of a forklift !!

While using a forklift to

transport 15 cardboard boxes
at once, some of the boxes
started to slip. The operator
climbed into the mast to adjust
the falling boxes.
Source: JICOSH

When the worker stepped between

the operator's seat and the mast
(without turning off the engine first)
he accidentally hit one of the control
levers, causing the mast to move.
He was crushed between it and the
Source: JICOSH
overhead guard.
No Speeding!!

Wikimedia commons
 Don’t leave your forklift unattended

A forklift is considered "unattended"

When the operator is 25 ft. or more
away from the vehicle even if it
remains in his view, or whenever the
operator leaves the vehicle and it is
not in his view.
When a forklift is left unattended,
forks must be fully lowered, controls
neutralized, power shut off, and Wisconsin Dept of Health Services

brakes set. Wheels must be blocked Where’s the operator??

if the truck is parked on an incline.
When the operator of a forklift is within 25 ft. of the truck still in his view, the load
engaging means must be fully lowered, controls neutralized, and the brakes set to
prevent movement, but the power does not need to be shut off.
 Propane-powered forklifts
and carbon monoxide

Source:Worksafe BC
Propane powered forklifts produce
carbon monoxide. The amount
depends on how well they are
tuned, but should be 1% or less at
the tailpile.

Carbon monoxide poisoning can occur when propane forklifts are used in
cold rooms, controlled atmosphere rooms, truck trailers or shipping
containers, or in warehouses or other enclosed areas that do not have
enough fresh air ventilation. If propane powered forklifts are used indoors,
they should be tuned up regularly and tested for carbon monoxide emissions
periodically.
Click here for more information on carbon monoxide and forklifts
 Safe Operation of Forklifts
and Other Powered Industrial Trucks

You must also have hands-on training on the specific truck

you will operating

... truck controls and handling are different

Click here to see L & I forklift operator training requirements

 Safe Operation of Forklifts
and Other Powered Industrial Trucks

Forklift Safety Quiz Questions

 Quiz

1. Because a forklift weighs more, it is easier

to stop it with the brakes than a car.

a) True

b) False
 Quiz

2. When driving down an incline with a loaded

forklift, you should:

a) Go down the incline backwards.

b) Raise the load before going down the incline.

c) Go down the incline frontwards.

d) Honk the horn.

 Quiz

3. If you are driving a forklift and it hits a hole and

starts to turnover, you should:

a) Jump out away from the direction it's falling.

b) Quickly turn off the engine.

c) Pull your arms in and hold on.

d) Crank the wheels the opposite way it's falling.

 Quiz

4. If you see a large puddle of hydraulic fluid under

the forklift, the first thing you should do is:

a) Use it to finish your task and then take it to

maintenance.
b) Clean up the puddle before someone slips
on it.
c) Inform maintenance or your supervisor and
not operate the forklift.
d) Find out where the leak is coming from.
 Quiz

5. Before you first enter a truck trailer with a forklift

you should:

a) Check to make sure the trailer has been

secured with wheel chocks

b) See if there is a spotter inside the trailer.

c) Get your supervisor's approval to enter.

d) Jump up and down on the dock board.

 Quiz

6. Special attachments to a forklift can be used

when:

a) The production manager approves it.

b) The forklift manufacturer approves it.

c) You have checked that it doesn‘t change

the forklift operation.

d) None of these.
 Quiz

7. The best way to handle a large load that reduces

visibility is to:

a) Honk the horn continuously so other workers

know you are moving.

b) Drive in reverse or use a spotter.

c) Raise the load so you can see under it.

d) Walk the route first so you know where to go.

 Quiz

8. A propane powered forklifts doesn‘t cause a

carbon monoxide hazard if:

a) It is well-tuned and there is plenty of

ventilation.

b) It is driven slowly.

c) It is used in place of a gasoline-powered

forklift.

d) It is a brand-new model.