Course: Forklift Safety

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Forklift Safety Course | 2

Course Outline

Module Description
Module 1 Introduction to Forklift
Module 2 Pre-Operational Inspection
Module 3 Safe Operating Procedures
Module 4 Maintenance
Written Assessment
Q&A

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Module 1 – Introduction to Forklift

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Forklift Components

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Types of Forklift

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Types of Forklift – Side Loaders

Other models have the forks on the side (called "Side Loaders“ ) or allow the
forks to pivot to the side (called "Front/Side Loaders”).

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Types of Forklift – Side Loaders

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Power Sources

• 2 main power sources for forklifts:

a) Internal combustion, which uses a traditional engine that runs
on liquid petroleum gas (LPG), compressed natural gas
(CNG), gasoline, diesel, or other fuels
b) Electric, which uses an on-board battery

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Importance of Forklift Safety

• On 10th July 2000, a 17 year old

worker was killed while
operating a forklift. He made a
right turn too sharply, which
resulted in the vehicle
overturning. His head was
caught between the overhead
guard and the ground, and was
crushed.

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Importance of Forklift Safety

• The results of the investigation

found that:
a) The employee had not been
trained on forklift operation
b) The vehicle was not fitted with
an operator restraint system
c) The vehicle had a passenger
that it was not designed for
Notice how the seat was not
d) The operator was under the secured to the vehicle, and it is
legal age required to operate a missing a seatbelt

forklift.

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Most Common Forklift Accidents

• Person or object struck by forklift

• Material falls on bystander or operator
• Operator is injured getting on or off equipment
• Forklift tips over because the rated load capacity is exceeded, or the load
is handled improperly

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Common Forklift Hazards

• Overloading
• Unsafe stacking
• Speeding
• Raised forks
• Unauthorized forklift operation
• Untrained forklift operators
• Lifting of persons on the forks
• Pedestrians and forklifts moving in the same vicinity
• Travelling on gradients
• Obstruction in the path e.g. overhead, blind corners
• Poor ground conditions e.g. slippery, uneven grounds
• Bad tire conditions e.g. no thread markings
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Video

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Module 2 – Pre-Operational Inspection

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Importance of Pre-Operational Inspection

• All forklifts will be inspected before each shift of operation

• If repairs are needed, it will be tagged “Unsafe Do Not Operate”
until repairs are completed
• A work order will be completed identifying repair needs

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Data Plates

• Know your forklifts before operating

• Data plates are attached to forklift body
• Data plate contains:
a) Type
b) Capacity
c) Load Centre
d) Forklift Weight
e) Lifting Height
• Forklifts must also be labeled as being
ANSI Certified

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Daily Inspection Checklist – Propane Forklift

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Daily Inspection Checklist – Electric Forklift

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Video

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Module 3 – Safe Operating Procedures

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Authorized Operators

• Only trained and authorized operators are permitted to operate

forklifts
• Establish control system to prevent unauthorized personnel from
operating the forklift
• Remove the key when the forklift is unattended

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Assessment of Work Environment

• Travelling path should be checked for overhead obstructions, uneven

ground, puddles of oil or potholes
• Watch out for overhead obstructions such as beams and cables

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Fuelling

• No smoking or use of open flames

• Shut off the forklift before fuelling
• Avoid breathing the fumes
• Be sure you are using the proper fuel
• Avoid overfilling the tank
• Clean up any spills before starting the unit
• Replace the fuel cap
• Watch for leaking fuel lines
• Wear eye protection and other protective gear

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Battery Charging

• Battery charging must be performed in the designated areas

• Inspect battery connectors for damage
• Ensure that the vent caps are functioning
• Tools and other metallic objects must be kept away from uncovered
batteries
• No smoking in battery-charging area
• Always pour acid into water, never pour water into acid
• Immediately clean up electrolyte spills
• PPE includes face mask, acid-resistant
gloves, and an apron

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Vehicle Entry and Exit

• Always enter and leave a forklift truck facing the vehicle

• If a sit-down vehicle tips over, remain seated in the operators seat
and lean away from the direction of the fall
• If a stand-up rider truck tips over, step backwards off the vehicle
to get clear.

Most people attempt to jump clear of a

tipping vehicle, and are crushed by the
overhead guard

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Loading

• Never exceed the rated capacity of your unit

• Forks must be spaced properly
• Be sure the load is stacked properly and is balanced
• Secure the load to the pallet
• Drive into load as far as possible
• Tilt the load back slightly & then lift it
• Watch for overhead objects or side objects
• Lower load 8 inches above ground level for travelling
• If a load blocks your view, travel reverse or get
assistance

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Loading

Forks must be spaced properly Be sure the load is stacked properly

and is balanced

Drive into load as far as possible

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Loading

TYPES OF FORKS
 HALF-TAPERED FORKS

- USED WITH HEAVIER LOADS

 FULL-TAPERED FORKS

- USED WITH LIGHTER LOADS

- USED WITH NARROW PALLETS

FORK ADJUSTMENT

FORKS SHOULD BE SPREAD AS

WIDE AS POSSIBLE TO ALLOW FOR
MAXIMUM STABILITY OF THE LOAD!

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Loading

REAL HEAVY PARTS REAL HEAVY PARTS

LOAD CAPACITY
6000 lbs LOAD CAPACITY
6000 lbs

6500lbs PROPANE ONLY 6500lbs

PROPANE ONLY

INCORRECT CORRECT

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Unloading

• Never stand under a load that is raised

• Always move slowly when the load is raised
• When stacking ensure load is level and secure
• Stack round objects tightly together and place a chock or block
• Be careful when backing out of a load where a pedestrian is in
your pathway

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Leaving a Forklift Unattended

• A forklift is considered to be unattended when the operator is

greater than 25 feet from it or the forklift is not in his view
• Fully lower forks
• Neutralize controls
• Set brakes
• Turn off the motor and remove the key
• If parked on an incline, block the wheels
• Never park in front of emergency exits

Unattended vehicles
must be shut down and
have controls neutralized
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Parking

• Lower the forks

• Set gear to neutral
• Set the parking brake
• Turn off the key

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Horns

• Sound your horn:

a) Before moving the forklift
b) Before reversing
c) At intersections
d) When travelling through doors
e) Anywhere your vision is limited or blocked

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Pedestrian Safety - Operators

• Operators shall be aware of the following:

a) Use warning devices to alert pedestrians
b) Maintain safe operating speeds
c) Slow down at intersections, blind concerns etc
d) Anticipate pedestrians stepping in travel path
e) Where possible, drive in the middle of aisle

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Pedestrian Safety - Pedestrians

• Pedestrians moving among forklift shall:

a) Stop and look both ways when approaching pathways or
intersections before proceeding
b) Keep a distance
c) Never walk or stand under the mast or load
d) Be ALERT

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What to Do If Your Forklift Starts to Tip Over?

• Always use seatbelts

• If your forklift starts to tip over:
a) DO NOT JUMP!
b) Stay in your seat within the cabin and go with the forklift
c) Hold on firmly and grip the wheel securely
d) Brace yourself with your feet

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Video

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Module 4 – Maintenance

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Maintenance

• Only authorized personnel can make repairs

• Ensure forklifts are serviced according to manufacturer’s
recommendations
• Vehicles not in a safe operating condition must be removed from
service
• Repairs to fuel and ignition systems must be made in designated
areas
• The battery must be disconnected before repairs on the electrical
system can occur

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Modifications or Additions

• Any modifications or additions that affect capacity or safe

operation must have the written approval of the manufacturer
• All marking plates, tags, or decals shall be changed accordingly

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Written Assessment

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Q&A

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 End of Training

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