06 Sep Forklift Safety-General Operating Rules

Forklift Safety – General Operating Rules

Operating a forklift requires training, skill, attention, and good judgment. Forklifts are heavy, powerful machines that can cause serious injuries or fatalities if operated improperly. Only trained, evaluated, and authorized employees may operate powered industrial trucks.

Operators are responsible for inspecting the forklift before use, following safe operating procedures, maintaining control of the truck and load, and watching continuously for pedestrians and other hazards.

Pre-Operation Inspection

Forklifts must be examined before being placed in service and at least daily. When forklifts are used continuously, they must be examined after each shift. Any condition that could adversely affect safe operation must be reported and corrected before the forklift is returned to service.

Check applicable items, including:

• Tires and wheels.
• Forks, mast, carriage, chains, and attachments.
• Steering and hydraulic controls.
• Service and parking brakes.
• Horn and other warning devices.
• Lights, alarms, and gauges.
• Seat belt/operator-restraint system.
• Engine oil, coolant, hydraulic fluid, and other fluid levels.
• Battery condition, charge, cables, and connections.
• Fuel system and fuel level.
• LPG/propane cylinder, connections, hoses, and securing devices.
• Visible fluid or fuel leaks.
• Overhead guard and load backrest.
• Safety labels and data plates.
• Any unusual noise, vibration, damage, or other unsafe condition.

Do not operate a forklift that is unsafe or in need of repair.

General Operating Rules

Follow these requirements whenever operating a forklift:

• Only trained and authorized employees may operate forklifts.
• Wear the seat belt or other operator-restraint system provided.
• Keep arms, legs, and other body parts within the operator compartment.
• Never allow unauthorized passengers or riders.
• Never engage in horseplay, stunt driving, or unsafe operation.
• Obey established speed limits and operate at a speed that permits the forklift to be stopped safely.
• Maintain a clear view of the direction of travel.
• Look in the direction of travel and check the surrounding area before moving.
• If the load obstructs forward visibility, travel with the load trailing when safe to do so.
• Maintain safe clearance from pedestrians and other vehicles.
• Slow down and sound the horn at cross aisles and other locations where vision is obstructed.
• Slow down before turning and avoid sudden starts, stops, and directional changes.
• Allow adequate clearance for rear-end swing when turning.
• Never drive toward a person standing in front of a bench, wall, rack, or other fixed object.
• Never allow anyone to stand or pass beneath elevated forks or loads.
• Keep hands and feet away from the mast, chains, forks, and other pinch or shear points.
• Maintain adequate clearance from overhead structures, doors, pipes, sprinklers, electrical conductors, and other obstructions.
• Never use wet, oily, or greasy hands when operating controls.
• Use only approved equipment and procedures when elevating personnel.

Traveling on Grades

Use extra caution on ramps and grades.

When operating a loaded forklift on grades exceeding 10 percent:

• Travel with the load upgrade.
• Keep the load tilted back when applicable.
• Raise the load only as far as necessary to clear the traveling surface.
• Travel slowly and maintain control.
• Avoid turning on ramps or grades.

When operating an unloaded forklift, follow the manufacturer’s instructions and applicable procedures for the specific truck.

Handling Loads

Forklift stability changes when a load is picked up, raised, tilted, transported, or deposited.

Before handling a load:

• Know the forklift’s rated capacity and never exceed it.
• Handle only stable or safely arranged loads.
• Use extra caution with long, tall, wide, or unusually shaped loads.
• Position the forks as widely as practical for the load.
• Insert the forks sufficiently beneath the load.
• Center and distribute the load properly.
• Approach loads slowly and squarely.
• Never attempt to move a load that exceeds the forklift’s capacity.

When picking up a load:

1. Approach slowly with the forks properly positioned.
2. Stop in front of the load.
3. Level the forks and insert them beneath the load.
4. Raise the load sufficiently to clear the supporting surface.
5. Tilt the mast back as necessary to stabilize the load.
6. Check behind the forklift and surrounding area before backing.
7. Travel with the load as low as practical while maintaining adequate ground clearance.

Depositing a Load

When placing a load:

• Approach the destination slowly and squarely.
• Stop before raising the load.
• Raise the load only to the height necessary.
• Position the mast as required to place the load safely.
• Lower the load carefully onto the supporting surface.
• Ensure the load is stable before withdrawing the forks.
• Look behind the forklift before reversing.
• Back away slowly, allowing adequate clearance for the forks and rear swing.

Never travel unnecessarily with an elevated load.

Loading and Unloading Trailers

Before driving a forklift onto a truck or trailer:

• Verify that the trailer floor can support the combined weight of the forklift and load.
• Ensure dockboards or bridge plates are properly secured and have adequate capacity.
• Set the vehicle’s brakes.
• Use wheel chocks or another approved vehicle-restraint system when required.
• Provide fixed jacks or other support when necessary to prevent an uncoupled semitrailer from tipping or upending.
• Maintain a safe distance from dock and platform edges.

Parking and Unattended Forklifts

Before leaving a forklift unattended:

• Fully lower the forks or other load-engaging means.
• Neutralize the controls.
• Set the parking brake.
• Turn off the power when required.
• Block the wheels if parked on an incline.

A forklift is considered unattended when the operator is 25 feet or more away while the truck remains in view, or whenever the operator leaves the truck and it is not in view.

When the operator is within 25 feet and the forklift remains in view, the forks must still be fully lowered, controls neutralized, and brakes set.

Refueling and Battery Charging

Refuel or recharge forklifts only in designated areas.

• Turn off the engine before refueling.
• Set the parking brake.
• Do not smoke or permit open flames, sparks, or other ignition sources in the area.
• Follow established procedures for LPG cylinder changes and battery charging.
• Clean up fuel spills and properly dispose of contaminated materials.
• Do not operate the forklift until spilled fuel has been cleaned up and any hazardous vapors have dissipated.
• Wear required PPE.
• Never use an open flame to check fuel, electrolyte, or fluid levels.

Remember

Inspect before operating. Buckle up. Keep loads low. Watch for pedestrians. Control your speed. Never exceed the forklift’s capacity.

If a forklift develops a safety-related defect or becomes unsafe during operation, stop using it, remove it from service, and report the condition immediately.