forklift safety training page 1 forklift safety training by: greg s. jarrett & jimmy r. mccraney

Forklift Safety Training


By: Greg S. Jarrett & Jimmy R. McCraney


Fork Lift Accidents

OSHA estimates that there are 680,400 accidents each year.

Over 100 resulted in death.

Of those reported nearly half suffered some type of injury.

“All Were Preventable”


OverviewOperators training requirements

Forklift Engineering Principles

Basic Operating Rules

Maintenance and Pre-start Safety Inspection

Vehicle Lockout

Forklift Safety Rules


Operator Training Requirements


Training

Employees must be trained and certified prior to operation lift trucks.

Training will be provided as formal instruction such as lecturescomputer learning, videotape, or written material.

Employee must be tested on knowledge and perform practical exercises using lift truck prior to certification.

Operators must be evaluated every three years.


Forklift Drivers Evaluation

COMPANY:_________________________________________________ Make ________ Model ________EMPLOYEE: _______________________________________________

YES NO

1. TESTING - JOB KNOWLEDGE ______ ______

2. OPERATOR DAILY INSPECTION ______ ______

3. SAFE REFUELING PROCEDURES ______ ______

4. CORRECT STARTING/STOPPING ______ ______

5. CORRECT BACKING PROCEDURES ______ ______

6. CORRECT STACKING/UNSTACKING ______ ______

7. CORRECT PARKING PROCEDURES ______ ______

8. OVERALL DRIVING OPERATION ______ ______

INSTRUCTOR COMMENTS: ____________________________________________________________

TRAINEE SIGNATURE: _____________________ TRAINER SIGNATURE: _____________________________

Sample only


COMPANY NAME:___________________________________________

NAME: ________________________________________________ DATE:___________

PLEASE CIRCLE THE CORRECT ANSWER

1. T F - Only trained and authorized operators shall be permitted to operate a powered industrial truck.

2. T F - When loads are raised and tilted forward, you change the center of gravity.

3. T F - Arms, legs, and other body parts should extend outside the overhead guard protection only when the truck is unloaded.

4. T F - The maximum weight of the load that your truck is allowed to carry is listed on the data plate.

5. T F - If a load is not carried as far back on the forks as possible, some load capacity can be lost.

6. T F - You can turn or stop a forklift suddenly if you are not carrying a load.

7. T F - Keep the forks as low as possible when traveling with or without a load.

8. T F - When traveling down a ramp or incline with a load, keep the counterweight upgraded.

9. T F - When following another lift truck, leave at least 3 truck lengths to allow room for stopping.

10. T F - Before entering a trailer, check to be sure that the trailer wheels have been properly chalked.

Knowledge TestSample only


Company: _________________________________________ Date: ________

This certifies that _________________________________________ has successfully completed the forklift safety training program and is authorized to operate the power industrial

trucks/equipment listed.

Equipment authorized to operate: Training/Refresher Training Date:

_______________________________ ____________________________

_______________________________ ____________________________

_______________________________ ____________________________

_______________________________ ____________________________

_______________________________ ____________________________

Trainer: _______________________ Employee: ______________________

FORKLIFT TRAINING CERTIFICATE



Data plates: lets the operator know

the following information:

Make Model Serial number Lift capabilities

Operators must know this information to

safely operate lift trucks

“Warning” OSHA can fine $25,000 for lift trucks that do not have data plates installed.


One style

Rear-end steering: rear-end swing createshazard situations if driversare not properly trained.


Fulcrum Point: is a lift trucks center point of balance during lifting operations.

The weight of the load affects the center of balance in relation to the counterweight. Load

Center of balance during load lifting (Fulcrum Point)

Counterweight


Never drive with load tilted, it changes the load center of balance

Load Center


Never drive with the loadraised too high it changesthe lift center of balance


Operating Requirements

&

Precautions


Basic Operating Rules

Employees must be trained and authorized to operate each specific lift truck. Must be re-evaluated every three years

Know controls and instrumentation. Location, what they do, and how they work.

Operating instructions Warnings, precautions, and hand signals used by company.

Pedestrian safety Know the areas where pedestrians will be working

Load manipulation Log/lumber stacking or loading of trucks.


Basic Operating Rules (continued)

Fork attachment operation and use limitation.

Drive in reverse if view is obstructed.

Know the terrain or environment that lift truck(s) will be driven

No horseplay, speeding or stunt driving allowed.

Always scan ahead to watch for pedestrians and blind spots


Should equal your average walking speed

or about 5 MPH.

Operating speed


Signs prohibiting unauthorized foot or vehicle

traffic in log unloading and storage areas shall

be posted.

1910.265 (d)(2)(i)(d)


Be aware of pedestrians at all times


One seat means only one person allowed on lift while moving.

No riders


No ridersOne seat means only one person allowed

on lift while moving.


Account for rear-end swing distance when backing.


Backing operationscan lead to incidentsand possible injury


Know your vertical limitationswhen lifting a load


Keep body parts insidethe cab at all times


Never add additional weight to lift a load


Pedestrians

Never allow anyone to walk under a load

See a hazard?


If visibility is restricted, drive in reverse.


If someone were accidentally struck lift forks, it is much less lift threatening to be hit

around the ankles than in the abdomen.

The rule to remember is to drive with the forks as low as possible.

Forks


Drive with load 4 to 6 inches off the ground or surface.


Know your correct distances when loading/unloading trailers


Watch for load shifts


When driving up a ramp or incline the rule is to drive up and back down


Drive Up

Back Down


Never raise someone using the forks


This is considered an imminent danger situation and could result in a $5,000 OSHA fine


Make sure dock plates are properly

in position.


See a loading hazard?

Chocks missing


Properly installed chock


Proper lighting during load/unload operations


Unsafe loading procedures can cause equipment damageand lead to possible injury.


Have someone assist when the load obstruct your vision

Truck Loading Operations


Maneuver the load slowly and safely



Center the load properly



Loading platformsthat are 48 or more inchesoff the ground must have barrierprotection to guard against fall hazard.


Dock plate placed in the up position to guard against fall hazard


Parking Lift TrucksThree Rules

Rule # 1Forks on the ground


Rule # 2Set Parking Brake


Rule # 3 If more than 25 feet away from lift it must be turned off.

See a hazard?

Never leave an unattended load elevated


Overhead Hazards


What about railroad crossings?


Forklifts should cross tracks at an angle -- not straight on

Because most forkliftshave a three-point

suspension and crossing straight on could cause the

lift to lose its center of balance


Crossing at an angle will ensure the load maintains its stability


Forklift Maintenance

&

Pre-Start InspectionRequirements


OSHA requires powered industrial trucks to have a documented pre-start inspection

prior to each shift.

Maintenance and Pre-start Inspection


Check forks for cracks

Some of the items to inspect:


Engine Fluids


Battery & Filters


Hydraulic lines


Check lights

Check FireExtinguisher


Seat Belts

Seat belts are requiredto be worn during alloperations.


Check Horn


Check gauges


To inspect the mast chains raise the fork about 6 inches

Next Slide


Mast chains should be tight. If they are loose it could

cause a load to shift


Refueling Operations.

Make sure lift is properly parked and brakes on


Park at a safe refueling distance from pump.


No one allowed in refueling area.


Wear personal protective equipment, if required


VEHICLE NAME

ENERGY SOURCE(S)

ELECTRICAL GRAVITY HYDRAULIC

MECHANICAL PNEUMATIC THERMAL

LOCKOUT/TAGOUT PROCEDURE

1. Turn ignition switch to the Off position.2. Disconnect battery before performing repairs on electrical equipment.3. Set brakes and chalk wheels.4. Lower blade or lifting device to ground.

CAUTION: if lifting device must be elevated for repairs there must be a positive means of support; chains, blocks, etc..)

5. Release hydraulic pressure by engaging controls or as required.6. Release pneumatic (air) pressure by valves, bleeding system or as required.7. Allow thermal energy to dissipate on engine, hydraulic systems.8. Allow moving parts to come to a “zero energy” state before performing

maintenance.

Vehicle Lockout


Vehicle Lockout

RESTORING TO NORMAL OPERATIONS

1. Account for all tools.2. Replace all guards and/or cover plates.3. Reconnect battery power.4. Inform affected employees that vehicle is ready for start-up.5. Vehicle in start-up condition.

ADDITIONAL SAFETY FEATURES

“CAUTION” : Do not allow anyone to walk under a raised blade or lifting device. Crushing injury can occur.

“Continued”


Use the correct lift for the job. Only trained and authorized employees are allowed to operate lift trucks. Complete a daily pre-start inspection. Do not park lift trucks in front of fire exits, isles, fire extinguishers, or electrical boxes. No passengers are allowed on lift trucks. Do not allow anyone to walk under raised forks whether loaded or empty. Stop and sound horn at all entrances and exit of buildings. Chock the rear trailer wheels when loading or unloading trailers at a loading dock. Do not park lift trucks on a grade. Do not raise or tilt the forks while driving. Drive with the forks raised only high enough to clear obstacles, preferably 4 - 6 inches. Wear of seat belts is mandatory. No smoking during refueling operations. Drive at the speed of normal walking, usually 5 MPH.

Forklift Safety RulesSample only


Forklift Safety is the DriversResponsibility

By: Greg S. Jarrett & Jimmy R. McCraney

forklift safety training page 1 forklift safety training by: greg s. jarrett & jimmy r. mccraney

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