Operating a forklift requires skill, training, and experience. Although it may seem as easy as driving a car, there are many factors that make driving a forklift much more difficult. Learning how to operate a forklift safely can help to prevent accidental injuries and possible death. The goal of forklift safety training is to help you achieve a work environment that is accident free and meets OSHA regulations.

 

This training module will help guide you through the steps of how to operate a
forklift safely. Topics you will learn about include:

1. How to safely operate a forklift.
2. Pre- and post-operation procedures.
3. Inspection and maintenance of the forklift.

 

A properly operated forklift, along with carefully followed safety procedures, will go a long way towards reaching the goal of a safe working environment at all times.

A forklift is one type of power industrial truck that comes in different shapes, sizes and forms. A forklift can be called a pallet truck, rider truck, fork truck, or lift truck. Yet, the ultimate purpose of a forklift is the same - to safely allow one person to lift and move large heavy loads with little effort. For the purposes of this training, a forklift is a small or large industrial truck with a power-operated pronged platform (commonly known as forks).

A forklift operator should be aware of the multiple parts on a forklift (see diagram above) in order to safely operate the forklift and be able to detect when an unsafe vehicle needs to be removed from service. Be sure to familiarize yourself with the parts on the forklift used within your company.

 

Note: The diagram above may or may not represent the type of forklift used in your company. Your instructor will be able to tell you which type of forklift you will be trained on.

 

Why is safety important where forklifts are concerned?
The Bureau of Labor statistics estimates that approximately 90,000 forklift accidents occur annually that result in employee injuries, lost time, or death. The four most common forklift-related deaths involve forklift overturns, workers on foot being struck by forklifts, workers being crushed by a forklift, and drivers falling from forklifts. It is estimated that inadequate training, at least in part, causes 20-25% of the accidents. So, during your forklift safety training, always keep in mind that you are being trained for the safety of not only yourself, but also others around you as well.

How can I become a certified forklift operator?

Receiving your certification for a forklift is very similar to gaining a driver's license for an automobile. You will be trained under the direct supervision of an experienced forklift operator and must successfully complete the following three parts of training:

• formal instruction such as a lecture, discussion, interactive computer learning, videotape and/or written material;
• practical training that includes hands-on demonstrations by the trainer and exercises by the trainee (on the type of forklift you will use for work); and
• an evaluation of the effectiveness of the training by observing your
  performance while doing actual work using the forklift.

 

Once you have been trained, you will then be required to take refresher training once a year. However, your supervisor may require you to go through refresher training if you have been involved in an accident or near-miss accident; you have received an evaluation that reveals you are not operating the truck safely; you are assigned to drive a different type of truck; or a condition in your workplace changes in a manner that could affect the safe operation of the truck.

Steering 

Operating a forklift is different than driving an automobile in many ways. For example, in most autos, the front wheels steer the vehicle in the direction you want to turn or travel. However, on some forklifts, the rear wheels control the steering. The rear end of the forklift swings in a circle around the front wheels that support most of the load you are carrying. Because of this large turning circle, always check to make sure there is room for the rear end to swing because it can swing out further than you expect and possibly cause an accident.

Braking
There is also a difference between a forklift and an automobile's capability to stop. Most autos have a front and rear brake system that allows the vehicle to stop quickly. A forklift, on the other hand, has rear steering that makes it difficult to stop a forklift quickly. In an auto, the steering system works together with the brakes to guide you to a smooth stop. But the rear steering on a forklift can make it difficult to swerve and react quickly. Therefore, remember to drive at a safe speed and be aware of your surroundings.

 

Weight of a forklift versus an auto
Although a forklift is smaller than a car a forklift may be two to three times heavier. The average forklift can weigh from 3,000 to 4,500 pounds. In order to balance heavy loads and help prevent the forklift from tipping over, a large counterweight is mounted on the rear of the forklift.

 

This counterweight is a part of the forklift's structure and should never have anything added to it in an attempt to balance the load out.

Forklift stability is an important topic because the leading cause of death and serious injury involving forklifts stems from overturns caused by forklift instability. Forklift stability can be described by four elements: the fulcrum point, center of gravity, the stability triangle and the load center.

 

Fulcrum Point
The fulcrum point may sound complicated, but think of it this way:
As children we all played on seesaws, which have a board that is balanced in the middle by a support piece. This support piece is what is called the fulcrum point. On a forklift, the fulcrum point is the front wheels. The fulcrum point serves as a support piece to balance the load and counterweight.

 

The illustration below displays this concept.

Center of Gravity (CG)
In addition to balancing both ends of the forklift, we must also balance in all directions. Balancing in all directions is better known as the center of gravity. The center of gravity is that point where all parts of a load or truck are balanced in all directions and will remain at rest. As a driver it is important to remember that a new center of gravity is created when you're handling a load (as opposed to an empty load) - one that combines both the load's and the truck's center of gravity. Think of it like riding a tricycle. If you peddle a tricycle around a corner and shift the center of gravity forward over the narrowest part of the tricycle, you are likely to turn over. But, if you shift your weight on the rear and place the center of gravity over the widest part of the tricycle, you are less likely to tip over.

Stability Triangle
That brings us to the stability triangle, the triangle on wheels. Think of the stability triangle as three imaginary lines that are connected by the center axle to the front wheels of the forklift. In order to maintain a stable forklift, you must keep the center of gravity within the stability triangle.

 

The most stable area while handling a load is close to the base of the forklift. If the load you are carrying moves too far forward from the forklift's base, it will more than likely tip forward.

Some factors that could cause instability are:

• Carrying the load too high.
• Excessively tilting the load forward.
• Operating on a decline.
• Heavy braking.
• Inappropriate use of forklift attachments.
• Off-center loads.
• Uneven terrain.
• Quick turns.

 

However, your potential to turn over can be reduced if you follow a few safety rules:

• Make sure the load is stable and safely arranged on the forks.
• Do not tilt the forks forward except when picking up or depositing a load.
• Keep the load low just above the pavement with the forks tilted back when traveling.
• Enter tractor-trailers or elevators squarely when picking up or depositing loads.
• Drive at a slow enough speed to allow you to stop safely.
• Drive slowly on wet or slippery surfaces.
• Avoid driving on unstable surfaces or where there are loose objects on the surface.

Load Center
Finally, keep the load center in mind when trying to remain stable or achieve stability. The load center of a forklift is simply the distance from the front face of the forks to the center of the load. The most important thing to remember is that the further you move from the load center of gravity, the lower the weight capacity your truck will be able to handle.

 

The maximum capacity that a forklift can handle can be found on the data plate located on the front of the forklift.

It is required that the forklift operator conduct a daily forklift inspection by using the company Forklift Inspection form that is located in the support center Forms tab. The inspection will ensure that you do not overlook certain hazards or equipment defects. 

 

You should conduct your inspection as follows: 

• Look around the forklift completely for any signs of defects.
• Inspect the general condition and cleanliness of the forklift.
• Check your oil, fuel and radiator level. (If the forklift is electric, check the electrolyte level, battery plug, and connections).
• Look for evidence of any damage (e.g., missing or loose bolts, nuts, chains, etc.)
• Observe the condition of wheels and tires.
• Honk the horn to ensure it is working properly.
• Make sure the forks are in working condition.
• Determine whether the chain anchor pins are worn, loose, or bent.
• Look for fluid leaks, damp spots, or drips.
• Make sure hoses are held securely in place.
• If authorized, check the battery cables and water levels.
• Look for objects on the floor or overhead that could lead to an accident.

 

Never use an unsafe forklift. If you discover that the forklift needs repair, do not
try to fix it yourself unless authorized to do so. Immediately take the forklift out
of service and report it to your supervisor. The damage it can cause if driven puts your safety and the safety of others at risk.

Mounting/ Dismounting
Special precautions should be taken when mounting and dismounting the forklift so that you dont slip, trip or fall. The correct way to mount the forklift requires you to use three points of contact which acts as a support system to prevent you from falling. This means that both of your hands and one foot should be in contact with the forklift at all times. Additionilly, you should always mount and dismount the forklift on the side without the gearshift. Never jump on or off of the forklift.

 

Safety Features
If your forklift has a restraint such as a seatbelt or a lap bar, you must use it. The restraints will hold you in the seat if you strike an object or if the forklift overturns. Failure to wear a seat belt can result in you being thrown outside of the forklift cage causing serious injury or death, so protect yourself by buckling up.

Also, for your own safety, never start a forklift or attempt to operate it from outside the vehicle. You must always start the engine and operate the forklift from the driver's seat to ensure the forklift does not jump out of gear and cause an accident. Failure to do so could cause injury to others or yourself, and damage to your surroundings.

Forks
Once the engine is started, but before you drive the forklift, make sure the forks are low to the ground. Forks should be positioned approximately 2-4 inches high while you are driving. However, you may need to adjust the forks if the planned route you are taking contains bumps, seams, or uneven terrain. Never allow anyone to walk or stand under the elevated forks (even if the forks are not loaded) because it may result in injury or accident.

 

Pedestrians
While you are driving, be sure to keep a safe distance away from pedestrians as they always have the right of way. In aisles where your vision is reduced, you should slow down at the cross aisle, and sound your horn to notify potential pedestrians that you are entering the area. Similar to the rules of the road, you should also yield the right of way to approaching pedestrians. Stop and allow them to pass before driving is resumed.

Loading Docks
Another safety precaution that you must take is to drive a safe distance from the edge of loading docks or ramps. Driving too close to the edge of a loading dock or a ramp may reduce your chance of stopping the forklift quickly due to slippery surfaces and/or the vehicle's weight. Also, drag racing or stunt driving should never be permitted as it could lead to a possible fatal accident.

 

Loads
Forklifts are often driven onto trucks or trailers bridge plate or up a load ramp. Prior driving a forklift onto a truck or trailer, check the flooring for any breaks or weaknesses. Also, make sure the trailer or truck has been properly secured. The truck brakes should be set and wheel chocks placed under the rear wheels to prevent the truck from rolling while the forklift driver is aboard. Never depend on anyone to make sure the vehicle is secured. Check it out for yourself to ensure your own safety!

Transporting loads can also involve a certain amount of danger, so it is imperative
that you take special care when handling loads. You should always inspect a load before picking it up to determine whether the load is stable. Ensure that the load will not slide or fall off during transit - no matter how pressed for time you are. Then ask yourself whether the weight of the load exceeds the amount that your forklift can handle. If the load is too heavy, you should break the load into smaller parts. When transporting a load up an incline, drive up the incline with the load in front of you. When exiting thew incline, drive back down with the forks still facing the uphill direction. This will help prevent the forklift from tipping. 

After inspecting the load, you can safely pick up the load by doing the following:

• Move squarely into position.
• Position the forks wide apart to keep the load balanced.
• Drive with the forks fully under the load.
• Tilt the mast backward slightly to stabilize the load and lift.
• If the load you are carrying obstructs your view, carefully travel in reverse, with the load trailing.

 

There are additional rules of thumb that will protect you and others while operating a forklift:

• Keep your feet, arms, and head inside of the forklift at all times to avoid an injury from unknown objects in the aisles.
• Do not allow anyone but the operator to ride on the forklift, unless the forklift is designed to carry more than one person.
• Stay alert to changing or unusual conditions so you can react to them.

When you are finished operating the forklift there are several precautions that should be followed to ensure the vehicle is securely shut down. When you are finished operating the forklift, lower the forks to the ground so that they cannot injure pedestrians. Set the gearshift to neutral, turn off the power (don't forget to remove the key) and set the brakes to avoid movement. Finally, dismount by holding onto the forklift with both hands and stepping down, one foot at a time, to give yourself the support to dismount safely. Do not jump from the forklift!

In addition to the daily pre-operation inspection you will perform, check the vehicle after usage to determine if any new defects exist. A forklift in need of repair can lead to many safety issues if it is not serviced in a timely manner. If you discover that a forklift is unsafe, you should immediately remove the forklift from operation so that no one attempts to operate it until it is repaired. Notify your supervisor about the maintenance issue(s) as soon as possible.

 

A forklift should be kept clean, free of clitter, excess oil, and grease to ensure that the controls and the vehicle operates properly. It is the responsibility of the operators of the forklift to clean the cab after each use. 

Fueling or charging a forklift is an important step in the operation of a forklift. There are many hazards involved, such as exposure to chemicals and flammable materials, so it is imperative for you to take all the necessary safety precautions. When refueling or charging the forklift, be sure to: 

• Identify where your eyewash station is located in case of an emergency in case you are exposed to hazardous materials.
• Not smoke or allow any open flames in the refueling/charging area.
• Make sure there is sufficient ventilation in case of fumes.
• Verify there is a fire extinguisher nearby.
• Put a barrier in place that protects the pump or charger against vehicle damage.

 

Changing a Battery

• Do not attempt to remove a battery, unless you h4ve been trained and authorized to do so.
• Only change the battery in a designated area to reduce the risk of injury.
• Always wear goggles and personal protective equipment to protect against acid burns.
• Turn the forklift off and set the brake before changing the battery.
• Secure the battery before lifting it out.
• Only remove the battery by using a conveyor, overhead hoist or equivalent machine that is designed for this purpose.
• Stand clear when removing the battery from the forklift.
  Make sure that the new battery is properly positioned and secured in the forklift.

Charging a Battery

• You should only charge or service the battery if you are authorized to do so.
• Review the forklift manufacturer's manual for recommendations before charging or maintaining the battery.
• When adding fluid to the battery wear safety glasses and a face shield for protection against electrolyte splash or spray.
• Properly position the forklift and apply the brakes before charging the battery.
• Remove any tools and other metal objects away from the top of uncovered batteries to prevent an explosion due to short-circuited terminals.
• Know where the nearest eyewash station or shower is located in order to flush out neutralized spilled electrolyte.
• If acid is spilled on your clothes, wash it off immediately with water.
• Make sure the ventilation system is working in the designated changing area before charging the battery.
• If you are charging the battery on the forklift, be sure to uncover the battery compartment to prevent a build-up of heat and hydrogen gas.
• Make sure that battery vent caps are not plugged, and the battery covers are open to dissipate heat.
• Unplug or turn the charger off before attaching or removing the clamp connections.
• Carefully attach the clamps to the battery in proper polarity (red to positive and black to negative).
• Always use proper safety procedures when cleaning up any spilled electrolyte.

Once you have completed this training and passed the test with a score of 100%, you must pass the Forklift Operator Evaluation & Certification process administered by a qualified person.

*NOTICE*

The Evaluation and Certification of a forklift operator must be completed by a company designated evaluator who has successfully completed this course.

The evaluator is required to complete the following competency verification by observing the forklift trainee successfully completing all the tasks listed in this checklist.

The trainee must score in the Fair or Good range of all aspects of the Evaluation in order to pass the observation and become certified.