1. BY
R.V.Mutusamy.

2. The following topics will be covered
How a forklift operates
Hazards of forklift
operation
How to use forklifts
safely

3. 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.

4. Forklift is
capable to lift
heights under
30 feet.
Load 1ton to
5ton in height

5.  OVERHEAD GUARD
 MAST
 CARRIAGE
 BACKREST
 LIFT CYLINDER
 TILT CYLINDERS
 FORKS
LOAD CAPACITY
6000 lbs
PROPANE ONLY

6. 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

7. 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
7

8. 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 8

9. 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

10. 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.

11. 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.

12.  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

13. LIFTING PRINCIPLE
CONSULT YOUR VEHICLE OWNERS MANUAL
6500lbs
REAL HEAVY PARTS
INCORRECT CORRECT
6500lbs
REAL HEAVY PARTS

14. 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.

15. 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
15

16. 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!

17. 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

18. 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

19.  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

20. Do not jump
Hold onto the steering wheel
Brace your feet
Lean away from the fall

21.  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.

22. Give them warning with
sensible one

23.  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.

24. Where’s the operator??

25. Pedestrians and forklift
moving in same place

26. Worn out
tyres

27. IF YOU ARE GOING OPERATE A FORKLIFT:
• DON’T DRINK ALCOHOL
• DON’T USE DRUGS
- DON’T PUT YOUR LIFE AND THE
LIFE OF YOUR COLLEAGUES IN
DANGER

28. 28

29. 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 debris29

30. 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
Daily check list
30

31. 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

32. 32
 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

33. 33
 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

34. 34
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.

35. 35
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?

36. 36
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

37. 37
Description of Accident
The deceased worker was involved in tallying stock stored on metal
racks within yellow boxes.

38. 38
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.

39. 39

40. 40

41. 41
Key Findings / Observations

42. HOW MANY SAFETY METHODS?
 Accident / Incident Investigation
 Accident Statistics
 Asbestos
 Behavioural Safety
 Construction
 Control of Contractors
 COSHH
 Culture
 Diploma Unit A
 Diploma Unit B
 Diploma Unit C
 Diploma Unit D
 Disability Discrimination Act (DDA)
 Display Screen Equipment - DSE
 Driving
 Electricity
 Environmental
 Ergonomics
 Excavations
 Fire Safety
 General Tools
 Hands
 Law

43. HOW MANY SAFETY METHODS?
 Lifting Operations and Lifting Equipment - LOLER
 Management of Health and Safety
 Manual Handling
 Noise
 Occupational Health
 OHSAS
 PAUSE
 Permit to Work
 Personal Protective Equipment (PPE)
 Policy
 Practice Questions and Answers
 Provision and Use of Work Equipment (PUWER)
 Reporting
 RIDDOR
 Risk Assessment
 Safety Induction
 Signage
 Stress
 Terrorism
 Training Tools
 Travel
 Work at Height
 Workplace Transport