Risk Management Department

1. Risk Management Department Forklift Safety April, 2008

2. Forklift Safety Introduction to Forklift Safety Operating a forklift is an important job. So important that the federal government requires that all lift truck operators be trained and authorized by their organizations. OSHA regulation CFR1910.178 states: "Only trained and authorized operators shall be permitted to operate a powered industrial truck."

3. Forklift Safety Introduction to Forklift Safety This training - together with the training provided by your supervisor on the specific operation of the forklifts you will be authorized to use – will give you the knowledge to operate a forklift in a safe, professional manner.

4. Forklift Safety Introduction to Forklift Safety During this training, you will learn about: Hazards of forklift operation Forklift accident statistics Safe forklift operation

5. Forklift Safety Forklift Hazards Forklifts can be dangerous to untrained persons because they operate differently than other vehicles such as cars and trucks. Forklifts: • Often weigh more than a car • Have reduced visibility • Often use rear-wheel steering • Operate in a more complex traffic environment • Can ride less smoothly due to tire types • Are more sensitive to shifts in center of gravity

6. Forklift Safety Forklift Hazards There are two general categories of hazards associated with forklift operations: Hazards of the forklift itself Hazards of the environment

7. Forklift Safety Forklift Hazards Hazards of operating a forklift: • Load capacity • Lift Height • Load stability • Visibility • Steering • Speed • Turning • Refueling • Maintenance

8. Forklift Safety Forklift Hazards Hazards of the environment: • Floors/Surfaces • Pedestrians • Obstacles • Blind spots • Narrow aisles • Intersections • Docks & trailers

9. Forklift Safety Forklift Hazards Not to mention hazards of the thought process!

10. Forklift Safety Accident Statistics Every year, there are 680,400 accidents involving forklifts in the United States Of these, there are 90,000 injuries!

11. Forklift Safety Accident Statistics These accidents break down as follows: • Tip-overs: 25.3% • Hit by forklift: 18.8% • Hit by falling load: 14.4% • Use of lift as elevator: 12.2% • Lift falls off dock: 7% • Improper maintenance: 6.1%

12. Forklift Safety Accident Statistics • Forklift overturned: 24% • Struck by falling loads: 17% • Struck by other truck: 14% • Fall from forklift: 14% • Crushed by forklift: 11% • Ran off loading dock: 8% • Worker making repairs on forklift: 6%

13. Forklift Safety Safe Forklift Operation There are several areas to consider to ensure safe forklift operations. These are: • Stability and center of gravity • Load capacity • Driving • Parking • Inspection • Refueling

14. Forklift Safety Safe Forklift Operation 1. Stability and Center of Gravity • Support points A, B & C form the stability triangle • Center of gravityis the point at which load isconcentrated • If center of gravityremains inside thetriangle, the truck won’t tip

15. Forklift Safety Safe Forklift Operation 2. Load Capacity • Check data plate • Don’t exceed maximum: • Load capacity • Load center • Lift height • Changing the load center changes the load capacity

16. Forklift Safety Safe Forklift Operation 2. Load Capacity • Place heaviest load against back of forks • Ensure loads are neatly stacked, stable, evenly distributed and secure • Place forks under the load as far as possible • Adjust forks to widest possible setting • Tilt forks back for added stability

17. Forklift Safety Safe Forklift Operation 3. Driving • Match speed to load and conditions • Decrease speed at all corners and sound horn • Watch for pedestrians and obey posted traffic signs

18. Forklift Safety Safe Forklift Operation 3. Driving • Safe driving • Keep forks as low as possible; don’t drive with load raised • Position forks to tilt back slightly • If view is blocked, travel in reverse • Watch for overhead obstructions

19. Forklift Safety Safe Forklift Operation 3. Driving • No Passengers • No lifting people • Use your seat belt • Keep hands and feet inside of truck • No standing under forks when raised • If following, maintain 3 length distance • No passing at intersections

20. Forklift Safety Safe Forklift Operation 3. Driving • Be aware of: oil spots, wet spots, loose object or holes • Avoid if possible: ice, mud, gravel, sand and soft dirt • Make sure area you are driving over can support the weight of the truck and the load

21. Forklift Safety Safe Forklift Operation 3. Driving • Ramps & Inclines • If empty: • Drive in reverse up the incline • Drive forward down the incline • If loaded: • Drive forward up the incline • Drive in reverse down the incline

22. Forklift Safety Safe Forklift Operation 3. Driving • Loading Docks & Trailers • Be aware of the edges of loading docks • Set brakes on trucks/trailers and choke wheels • Inspect interiors • Ensure that dock plate & interior surfaces can support weight • Watch clearance

23. Forklift Safety Safe Forklift Operation 4. Parking • Set forks flat on floor • Place controls in neutral • Shut off engines • Set brakes • Block wheels if on an incline • Do not block emergency areas

24. Forklift Safety Safe Forklift Operation 5. Inspection – pre- and post-trip: • Hydraulics • Uprights • Forks • Attachments • Leaks • Tires/wheels

25. Forklift Safety Safe Forklift Operation 5. Inspection – pre- and post-trip: • Brakes • Steering • Controls • Lights & signals • Engine

26. Forklift Safety Safe Forklift Operation 5. Inspection – pre- and post-trip: • Horn • Fluid levels • Battery • Hour meter Report problems to your supervisor!

27. Forklift Safety Safe Forklift Operation 6. Refueling • Park in designated recharging/refueling area • Ensure adequate ventilation • Don’t smoke • No open flames, sparks, or electric arcs nearby • Have fire extinguisher nearby • Use proper personal protective equipment • Always check lines, wires, hoses for leaks

28. Forklift Safety Safe Forklift Operation 6. Refueling – Recharging Electric Trucks • Wear splash proof goggles and protective clothing • Check electrolyte level before charging • Keep tools and metallic objects away from battery top • Do not pour water into acid • Watch for spilled materials • Ensure battery is secure

29. Forklift Safety Safe Forklift Operation 6. Refueling – Gasoline or Diesel Trucks • Turn off ignition and lights • Make contact between spout and fill pipe before pouring • Check for leaks • Clean up any spills • Make sure you use an approved container

30. Forklift Safety Safe Forklift Operation 6. Refueling – Gasoline or Diesel Trucks • Shut valve; let engine run until it stalls • Turn off ignition and lights • Check for leaks and damage to connections • Wear protective clothing • Remove empty tank and store it • Install new tank securely

31. Forklift Safety You are finished! You have finished the Forklift Safety training. Download the quiz from the link on the Risk Management Department website training page. Print the form and be sure to write your name, location and employee number in the spaces provided. Complete the ten questions and have your supervisor send it to the Risk Management office.