BY

B.ANANDAN
 The following topics will be covered

How a forklift operates

Hazards of forklift
operation

How to use forklifts

safely
 Forklift is a machine used
to transport heavy materials from one
place to another place (Short distance
only) to stack, unstack, to load &
unload material.
Forklift is
capable to lift
heights under
20 feet.
Load 1t to ton
5ton in India
 OVERHEAD GUARD

 MAST

 CARRIAGE

 BACKREST
LOAD CAPACITY
6000 lbs

 LIFT CYLINDER
PROPANE ONLY

 TILT CYLINDERS

 FORKS
Only Trained authorized personnel are
permitted to operate a forklift.
Badges or other visual indications shall be
displayed on the body of the operators at all
time during operation.
The operator should not drive the truck up to a
person standing in front of a bench or other
object.
The operator should not carry loads heavier
than those for which the truck rated. 6
Forklift controls operated only from
driver’s seat
Never block exits or emergency equipment
Smoking is not permitted when operating the
forklift
No person should stand under elevated
portion of lift truck

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The operator should avoid making fast starts,
sudden stops and quick turns.
The operator should report all accident
involving personnel, building structures and
other equipment.
Operation on main roads outside the factory
premises should be permitted only with proper
authorization of local transport authority.
Unless specifically authorized to do any repair,
the operator should not make repairs,
alterations or adjustments to the equipment. 8
Workplace hazards: ramps, slippery floors,
poor lighting, congestion
Loads: large or bulky, uneven weight, broken
pallets, poor stacked
Pedestrians: horseplay, unaware of forklift
areas, not paying attention
Almost all counterbalanced powered industrial trucks supported at three points. This is
true even if the vehicle has four wheels. The truck's steer axle is attached to the truck by
a pivot pin in the axle's center. When this point is connected to the front wheels with
imaginary lines, this three-point support forms a triangle called the stability triangle. So
long as the center of gravity remains within this stability triangle, the truck is stable and
will not tip over.
A forklift balances a load with a counterweight at the back. The
front wheels act as a pivot or balance point. The center of gravity
moves upward when the forks are raised.
 While carrying a load near the maximum allowable capacity, be
aware of the following:
 Danger of tip over
 Danger of losing load
 Danger of being struck by falling load
 LIFTING PRINCIPLE

REAL HEAVY PARTS

REAL HEAVY PARTS

6500lbs
6500lbs

CONSULT YOUR VEHICLE OWNERS MANUAL

INCORRECT CORRECT
Loose loads are subject to falling. Off center loads can also be
subject to falling or cause the forklift to tip over. The photos
below show the correct way to load pallets.

Avoid using damaged pallets.

Before raising a load, understand:
Approximate weight of the load
Location of the load’s center of gravity
Inspect load for stability, projections,
damaged pallets before lifting
Restack unstable loads
Never place weight on the back of
a lift truck to increase its capacity
Towing always done from rear towing pin
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When removing a load from a high rack:
 Slowly back out with the load
 Stop when it clears the rack
 Lower the load to the floor
 Don’t lower the load while moving!
Use extra caution when handling loads that approach the truck's
maximum rated capacity:
 Tilt the mast & forks back and position the heaviest part of the
load against the carriage.

 Travel with the mast tilted back to keep the load stable.
 Never travel with the load tilted forward. Tilting the load
forward increases the load distance and makes the load less
stable
Always drive with the load on the uphill side - go backwards
driving down the incline and frontwards going up the incline to
prevent tipping or losing control of the forklift.

If no load on the forklifts, do the opposite with forks pointing down

the ramp
 Driving too fast around a
corner

 Driving off edge of

platform, ramp, road or
other surface

 Driving an indoor forklift

outdoors on rough, uneven
ground

 Turning on an incline or hill

Do not jump
Hold onto the steering wheel
Brace your feet
Lean away from the fall
 Slow down and sound horn at
intersections, corners, and wherever your
vision is obstructed.
 When provided, use flashing warning
light or backup alarms when traveling in
reverse.
 Always look in the direction of travel.
 Signal to pedestrians to stand clear.
 Do not allow anyone to stand or walk
under upraised forks.
 When possible, make eye contact with
pedestrians or other forklift operators
before moving in their path.
Give them warning with
sensible one
 No one else on the forklift except
the operator, unless the forklift
has a seat for a rider.
 Always drive with the forks
lowered and lower forks to floor
when parking the forklift.

Watch overhead clearances – especially entering or exiting

buildings or when you are raising a load on the forks.
Where’s the operator??
Pedestrians and forklift
moving in same place
Worn out
tyres
Refer Safety and Book
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Forklift properly disconnected
Forks down, key off, neutral gear, parking brake on
Left/right side
Tire condition, tight lug nuts, no debris around axle,
overhead guard is solid, no debris behind the mast
Front
Forks in good shape, fork pins in place, backrest
solid, mast & chains greased, hoses in good shape
Rear
Counterbalance bolt is tight, radiator clear of debris
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Non-moving checks
Gauges, lights, horn, Reverse alarm, blinking
warning light, operate the tilt & lift
mechanism, check the parking brake
Moving checks
Check the running brakes, check the steering
Look for oil or water leaks on the floor

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Always look in the direction of travel
Keep body inside the cage
When moving, the mast must not be
raised
Sound the horn
Operate at safe speeds
When turning, watch rear end swing
Clearance under overhead installations 31
 Report to your supervisor on any forklift damage or
problems
 Don’t use a forklift to lift worker
 Use caution on slopes or ramps
 While on slopes, tilt the load back and raise it above road
surface
 Don’t raise or lower the forks while the forklift is moving
 Don’t handle loads that are above the weight capacity of
the forklift
 Follow the speed limit

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 Slow down and sound the horn at crossings and locations
where view is blocked
 Focus on the travelling path and keep a clear view of it
 When leaving a forklift, pull the parking brake, lower the
forks and neutralize the controls
 Slow down and sound the horn at crossings and locations
where view is blocked
 Focus on the travelling path and keep a clear view of it

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The engine of diesel forklift should be stopped before
refueling.
It should not be restarted unless the fuel line has been
removed from the forklift and the filler cap has been
properly replaced on the tank.
Particular attention should be paid to avoid fuel spilling
over the engine or exhaust system.
If spillages occur the fuel should be wiped away properly
before restating the engine.
Contact between the metal outlet of the refueling hose and
the fuel tank opening on the forklift should be maintained
at all time during refueling process.
Naked flames should never be used to check fuel levels in
tanks. 34
1 Does the forklift specification meet the operating requirement?
2 Is forklift maximum load capacity clearly printed on the forklift
body?
3 Does the forklift maximum speed controlled?
4 Do horn, reversing beeper, proximity indicator and flashing light
function properly?
5 Are the forklift maintenance performed regularly?
6 Are forklift maintenance and repair records maintained?
7 Are the tires in good conditions?
8 Forklift breaks conditions
9 Is the steering work well?
10 Does the gear control work?
11 Are the left, right and rear view mirrors available and clear?
12 Do all indicators and gauges function properly?
13 Are there any liquid leaks from the forklift?
14 Are Mast, Lifting system are in good condition?
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Workplace Premise: Warehouse premise in a distribution
park
Forklift: 3 ton (load capacity)
Work Activity: Deceased was taking stock of goods to be
transported out of the warehouse. He squeezed
through the gap between two racks and was crushed when
a forklift pushed the racks closer to make space for more
racks.
Nature of Accident: Crushed between objects

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Description of Accident
The deceased worker was involved in tallying stock stored on metal
racks within yellow boxes.

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The deceased worker was conducting checks in between two metal racks
just prior to the accident.
To free up space for more cargo, a forklift operator used his forklift to push
the adjacent metal racks. The deceased worker was trapped in between
the metal racks. Deceased worker was found dead an hour later.

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 Workplace Premise: Factory repackaging waste paper
 Forklift: 3 ton (load capacity)
 Work Activity: Deceased was operating the forklift on a metal ramp to load
up compressed bales (blocks) of waste-paper into a container
 Nature of Accident: Forklift overturned and crushed Worker

 The forklift was loading blocks of compressed recycled papers ("paper

bales") into a 40 ft long container stationed at the end of the ramp. The ramp
was propped up by paper blocks. Another forklift was used to move the
paper blocks onto the ramp for loading.

 While the deceased was in the process of loading a paper block, the forklift
suddenly reversed out from the side of the ramp and toppled off the ramp.
The deceased was pinned onto the ground by the forklift and was killed.

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Key Findings / Observations

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