Machine Guard Awareness

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The Premier Resource for Environmental, Health,
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ForkliftOperationsSafety Driven
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Introduction
Remember when you got your first set of wheels?
For most of us, there was a learning curve and a
few challenges with staying upright.
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Introduction

Then we got older and other drivers only
complicated things. As our skills continued to
develop, we took on new challenges, but not
without some bumps along the way. Fortunately,
those were only minor mishaps back then. But its
different today. If youre a professional
forklift driver, your experience, skill and good
judgment are critical to preventing serious
injury Remember when you got your first set of
wheels? and maintaining a safe work environment.
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Introduction

Forklifts are a common sight in most factories
and warehouses, used to carry, push, pull, lift
and stack loads efficiently and with less strain
on workers, but, unfortunately, many workers
underestimate how dangerous forklifts can be.
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Introduction

If you drive a car its a mistake to assume you
already know all you need to know to drive a
forklift there are significant differences
between the two vehicles. For example, forklifts
tip over much more easily than cars do. Adding to
the risk, the average forklift weighs about 9,000
pounds, or about three times more than the
average car.
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Introduction

Obviously, staying stable and upright are
extremely important, and forklifts are
counterweighted in the back to balance out the
load being carried at the front, but critical to
your safety is knowing how to handle that load
and staying within the weight capacity of your
forklift. Another important difference from
automobiles is that forklifts steer from the rear
wheels.
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Introduction

This is valuable in warehouse and factory
settings because it allows forklifts to make very
tight turns but it also means that its that
much easier to tip a forklift over if its turned
while traveling at too high a speed.
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Introduction

According to the Bureau of Labor Statistics,
each year nearly 100 workers are killed in
forklift accidents and another 20,000 workers
are seriously injured. The most common causes of
forklift-related fatalities are forklifts
overturning (22 percent), forklifts striking a
pedestrian (20 percent), drivers or other
employees being crushed by a forklift (16
percent), and drivers falling from their forklift
(9 percent). To prevent accidents like these, the
Occupational Safety and Health Administration, or
OSHA, mandates that every forklift operator must
be properly trained and certified before using
the equipment.
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Daily Inspections

Even if you operate your forklift in a safe
manner, if the equipment itself is defective or
damaged it can put you and your co-workers at
risk.
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Daily Inspections

For this reason, forklifts must be inspected at
the start of each shift. Because forklifts and
other powered industrial trucks vary in design
and may be powered by battery, internal
combustion or liquid propane, for the complete,
specific inspection youll need to consult the
manufacturers recommendations or your supervisor.
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Daily Inspections

A checklist thats appropriate to your forklift
can help guide you through a detailed inspection
of the equipment.
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Daily Inspections

Begin with the forklift shut off, and include
these parts in your inspection The forks are
they spaced equally and are the blades free from
cracks? Is the top clip retaining pin and heel
in good condition? Whats the condition of the
mast assembly? Do the hydraulic hoses and mast
chains have any leaks, cracks or other visible
defects?
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Daily Inspections

When checking this area, never place your hands
inside the mast to test the tension of the
chains use a stick or other device. Look the
tires over for excessive wear, and check for cuts
and gouges in the rubber. Make sure the
overhead guard isnt bent, cracked or loose. If
theres a seatbelt, is it accessible and free of
damage? Is the vehicles engine oil at
the appropriate level?
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Daily Inspections

Depending on the manufacturers recommendation or
your facilitys policy, you may also need to
check other fluid levels as well.
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Daily Inspections

After this part of the inspection is over, start
the forklift and continue with the inspection,
including The brakes are they reliable, and
do they stop the vehicle smoothly rather than in
a sudden, gripping fashion that can cause
tipping? Check that the head, tail and
warning lights work and are aimed correctly.
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Daily Inspections

Test the horn. And make sure the gauges and
instruments function properly. Check the
steering wheel is it responsive and free of
excessive play? Are the control levers labeled?
And do they move in a way thats neither too
loose nor too binding, returning to neutral when
released?
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Daily Inspections

Your checklist will have additional parts to
inspect. While it may seem like a lot to look
over each day, its your life on the line and
equipment that functions properly is critical to
staying safe. If anything doesnt pass
inspection, note it on the paperwork and inform
your supervisor. Any vehicle thats defective,
damaged or otherwise unsafe must be removed from
service, until it can be repaired.
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Maintaining Stability

Because overturning is the number one cause of
forklift related fatalities, its critical that
you understand how to keep your vehicle stable
and upright.
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Maintaining Stability

For forklift operators, a few important concepts
can help them maintain critical stability. The
first is known as the stability triangle. If we
view a forklift from underneath, the stability
triangle would extend from the two front wheels
to the center of the rear axle.
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Maintaining Stability

We can visualize the vehicles center of gravity
as a small circle this circle moves about as
the vehicle is used. For example, the center of
gravity shifts forward when loading the forks,
when raising the forks, or when braking. It
shifts to the side when the forklift turns or if
the mast is struck by falling objects. At all
times, it should remain within the stability
triangle if the circle (or center of gravity)
moves out of the triangle the vehicle will tip
over.
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Maintaining Stability

What kinds of activities can cause this to
happen? There are several Starting or stopping
too fast Slow, gradual starts and stops help keep
your vehicle stable. Traveling with an elevated
load Elevated loads are less stable, so travel
with your load just high enough to clear the
floor typically about 4 inches off the ground.
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Maintaining Stability

Turning the forklift while traveling too
fast Instead, make turns cautiously and at a
reduced speed. Jerky movements while operating
the hydraulic system. Again, easy, smooth
movements are more stable.
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Maintaining Stability

Carrying a load thats too heavy Just because the
forks can lift a heavy load, dont assume its
safe to do so. A properly loaded forklift does
not exceed the rated capacity of the vehicle
which can be found on the data plate thats
attached to the forklift.
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Maintaining Stability

Turning the forklift while traveling on a hill or
incline. When traveling on a grade of 10 percent
or more, always carry a load with forks pointing
upgrade that means when you go down a ramp with
a load youll have to travel in reverse, so turn
your head to look in the direction of travel.
When traveling without a load, keep your forks
pointing downgrade whether youre moving up or
down the ramp.
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Maintaining Stability

What should you do if your forklift does
overturn? According to OSHA The procedure to
follow in the event of tipover varies depending
on the type of tipover and the class of forklifts
that you may use in your facility.
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Maintaining Stability

For tipovers on sit-down counterbalanced trucks
follow these steps Dont jump. Stay in the
forklift. Hold tight to the steering
wheel. Brace your feet. Lean away from the
impact. And, lean forward.
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Maintaining Stability

Finally, its important to emphasize that during
a tipover seatbelts are nearly 100 effective at
preventing fatalities. If your vehicle has a
seatbelt, always buckle up before operating the
equipment. For other types of forklifts, consult
the operators manual or contact the
manufacturer for the correct procedure to follow
in the event of a Tipover.
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Driving a Forklift

When youll be operating a forklift, choose
slip-resistant footwear and avoid loose clothing
and dangling jewelry.
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Driving a Forklift

Before mounting the vehicle check your boots for
grease and make sure your hands are dry so that
they wont slip.
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Driving a Forklift

When climbing on, face the forklift. Maintain
three points of contact, with both hands and one
foot, or both feet and one hand in contact with
the forklift at all times, but avoid grasping the
steering wheel - if it turns in your hand while
you enter or exit it could throw you off balance.
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Driving a Forklift

Use the same care when exiting the forklift
never jump off the equipment. Once seated, if the
forklift is equipped with a seatbelt, always
fasten it. Before moving, make sure that the
forklift has good clearance and look for
pedestrians in the vicinity.
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Driving a Forklift

The appropriate height for the forks when
traveling is about four to six inches at the
tips, and two inches at the heels, which is low
enough to provide stability, but high enough to
clear most uneven surfaces and debris. Before
starting out always look in all directions to
make sure the way is clear of pedestrians and
other traffic. Remember to make your stops and
starts smooth and gradual, and keep your speed
low enough that you can bring the forklift to a
safe stop if something unexpected occurs.
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Driving a Forklift

While traveling keep your head, hands and feet
inside the vehicle to avoid injuries from falling
material or from protruding objects outside the
cab. When crossing aisles or other locations
where vision is obstructed, slow down and sound
your horn. Be aware of other motorized traffic
and maintain a safe distance of at least three
truck lengths when following behind another
forklift.
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Driving a Forklift

At intersections, blind spots or other dangerous
locations, do not pass other forklifts traveling
in the same direction. When turning, slow down to
maintain balance, and turn the steering wheel in
a smooth, sweeping motion.
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Driving a Forklift

As you move always look in the direction youre
traveling. If youre carrying a large load that
blocks your view, travel in reverse remembering
to turn and face the rear, sound your horn before
moving, and travel slowly. While moving in
reverse, avoid grabbing the overhead guard for
support, as this could expose your fingers to a
serious injury.
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Driving a Forklift

Remember that a forklift striking a pedestrian is
the second most common cause of forklift-related
fatalities, so give pedestrians plenty of room
and stay alert for the unexpected, especially
in aisles and doorways. Use your horn whenever
you start out, or before entering an
intersection, but never assume that
pedestrians have heard you, especially in a noisy
work environment.
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Driving a Forklift

Always give pedestrians the right-of-way, and
never drive up to anyone who is in front of a
bench, wall or any other fixed object a brake
failure or pushing a wrong lever could pin them
between the forklift and the object. And, of
course, never allow a pedestrian to ride on your
forklift unless its specifically designed to
accommodate passengers.
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Driving a Forklift

Watch for hazards in the environment slow down
for wet and slippery floors and avoid running
over debris. When going over railroad tracks,
cross diagonally whenever possible. If you work
on a dock, avoid driving along the edge of the
dock. Before driving onto a semi-trailer, verify
that the driver has set the brake and chocked the
wheels. Also make sure that the dockboard or
bridgeplates are properly secured and that youre
load is within their rated capacity.
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Driving a Forklift

Finally, check that the floorboards are in good
condition and will support the combined weight of
the forklift, the load, and you.
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Driving a Forklift

When parking your forklift, choose an authorized
location that wont block traffic. If youll be
moving more than 25 feet away from the forklift,
or to a location where you cant see it, the
equipment is considered to be unattended. If this
is the case, before exiting the forklift lower
the forks to the ground, set the controls to
neutral, set the brakes and turn off the power.
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Driving a Forklift

If youll be dismounting the equipment but
staying within sight and within 25 feet, you must
at least lower the forks to the ground, set the
controls to neutral and set the brakes.
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Driving a Forklift

Depending on its power source, you may be
required to either refuel your vehicle, or
recharge it by plugging in or changing out the
battery.
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Driving a Forklift

When performing any of these procedures always
follow your facilitys safety policies, including
wearing the appropriate Personal Protective
Equipment, and knowing the location of the
nearest eyewash stations and fire extinguishers.
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Handling Loads

Before handling any load, you must know the
capacity rating for your forklift in other
words, how much weight the vehicle can carry.
This can be found on the lift capacity plate
attached to the vehicle.
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Handling Loads

Its important to realize that, for this number
to be accurate, you must stay within the
vehicles load center. The load center is the
distance from the vertical face of the forks to
the loads center of gravity.
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Handling Loads

The standard pallet in inches measures 48 by 48,
and the center of gravity of a well-balanced load
would normally fall at the 24 inch mark. For this
reason many forklifts are designed with a load
center rating of 24 inches.
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Handling Loads

When thats the case, a full capacity load can be
safely lifted to the maximum height of the
forklift (as long as the load is kept vertical).
As the load center increases (moves farther out
from the forklift) the amount of weight that can
be safely lifted decreases.
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Handling Loads

For this reason, many data plates list three
lifting capacities based on different load
centers. If you have questions about the safety
of a load, talk to your supervisor before
making the lift.
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Handling Loads

Before picking up a load, spread your forks as
far apart as possible for greater
stability. Depending on the forklift this can be
done manually or with a hydraulic fork
positioner. Approach slowly and square up on
the center of the load with the forks in the
low-to-the- ground traveling position.
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Handling Loads

The goal is to center the weight of the load
between your forks. Stop when the forks are about
a foot in front of the load and set the brake.
Before raising the forks check that
theres adequate overhead clearance, then bring
the forks to the proper height.
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Handling Loads

With the forks level, slowly drive forward until
the load is resting against the backrest. If
pallets are closely stacked, however, be careful
that the forks do not go through to the other
side where pallets in the second row could get
damaged or snagged. Lift the load straight up
until its high enough to clear whatever is under
it, then tilt the forks back slightly for added
stability.
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Handling Loads

After looking for traffic behind you, slowly back
out about a foot to double-check that the load
will clear then back away far enough to clear
the stack, and lower the load for traveling.
Never turn or travel with the forks in an
elevated position.
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Handling Loads

When setting a load down its important to
remember that falling material and
collapsing loads become a serious danger to
anyone caught underneath.
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Handling Loads

To help prevent injuries, when shelving and
stacking material keep these guidelines in
mind Make sure the loads destination is flat
and stable. If your destination is a rack or
storage loft, stay within its load
bearing capacity. Set the heaviest loads on the
bottom tier.
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Handling Loads

Set the lightest loads on the top tier. Never
stack heavy loads on top of light loads. Follow
maximum stacking quantities printed on the loads
packaging or paperwork.
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Summary

When we were young, as we accumulated knowledge
and gained experience, we mastered new skills.
Today the stakes are higher because the risks are
greater, but your knowledge and skill as a
professional forklift driver, along with your
commitment to your facilitys safety program,
help to create a safer work environment for you
and your co-workers.
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