Forklift Basics

Editor’s Note: The following feature is an edited excerpt from “The State of Washington Forklift Safety Guide,” which was produced by the Washington State Department of Labor and Industries. The full guide can be found here.

A forklift is a type of “powered industrial truck.” Like other powered industrial trucks, its purpose is to move, carry, push, pull and lift a material load [and] then stack it or place it in a storage rack (tier). Forklifts come in many sizes and capacities. They can be powered by batteries, propane, gasoline or diesel fuel. Some are designed to be used in a hazardous location or atmosphere where an ordinary forklift might cause a fire or explosion.

SURFACE CONDITION

The surface a forklift operates on can cause serious safety problems. Loose objects, bumps or depressions can cause you to lose control of steering, bring you to a sudden unplanned stop or cause you to drop your load. A soft dirt surface can cause a wheel to sink and destabilize an elevated load and the forklift.

Any surface a forklift drives on must be able to support the forklift and its load with a safety factor of four. If a 7,000-pound forklift is carrying a 3,000-pound load, then the floor must be able to support 40,000 pounds. Remember that nearly the full weight of the load plus a part of the weight of the forklift may be centered near a single wheel.

Wet, oily or icy surfaces should be avoided. Clean up surfaces as soon as possible.

TRAVELING

The basic rule for traveling is that you maintain control of your forklift at all times. Other rules include:

• Operate a forklift only while in the seat or operator’s station. Never start it or operate the controls while standing beside the forklift.
• Never allow passengers unless the forklift was designed for a passenger.
• Do not put any part of your body between the uprights of the mast or when traveling.
• Always look in the direction of travel and keep a clear view of the travel path. Travel in reverse if the load blocks your view.
• Always observe posted speed limits at your workplace. A forklift should not be driven faster than a quick walking pace.
• Keep a distance of at least three forklift lengths between you and any forklift traveling in front of you.
• Do not pass a forklift traveling in the same direction if it is at a blind spot, intersection or other dangerous location.
• Never drive a forklift up to anyone in front of a bench or other fixed object.
• Never allow anyone to walk or stand under the elevated forks—even if the forks are not carrying a load.
• Check that there is adequate clearance under beams, lights, sprinklers and pipes for the forklift and load to pass.
• Never engage in stunt driving or horseplay.

DRIVING ONTO TRUCKS, TRAILERS AND RAILROAD CARS

Forklifts are often driven onto trucks, trailers or railroad cars over a dock board (also known as a bridge plate) at loading docks. If the truck, trailer or car is not secured to the dock or otherwise chocked, it can move over time. The dock board can then fall between the trailer and the dock as the forklift crosses it.

You can secure wheel chocks with chain at each loading dock bay and tell truck drivers that they must place them in front of the rear wheels. Another way of securing the trailer is to use a vehicle restraint system mounted to the dock that clamps onto a bar below the trailer as it backs into place. This system will signal when the restraint is engaged or if there is a problem.

The pavement at some loading docks slopes downhill toward the loading dock. This is not a substitute for chocking wheels.

Sometimes a trailer is left at a loading dock without the tractor attached. Use trailer jacks to prevent the trailer from up-ending when a forklift drives to the front of the trailer to load or unload.

A portable dock board must be secured in place to prevent it from moving. Some boards have pins that are inserted into the sides and project below the board. This prevents the board from moving toward the dock or toward the trailer. To prevent crushed fingers and make for safe handling, a portable dock board must also have handholds or lugs that allow the forklift to pick it up.

Keep a safe distance from the edge of a loading dock or a ramp. The edge must be painted yellow or with alternating yellow and black diagonal stripes to warn of both the fall hazard and the potential to be crushed by a trailer backing into the dock. Some loading docks have a bull rail that prevents a wheel from slipping off the sides of ramps or edges of the dock where a forklift would not have to cross to enter a trailer.

Any part of the dock edge that is 4 feet or more above the adjacent surface must have a standard guardrail. Removable rails (such as chain rails) and posts can be used at the place where trucks or trailers will be loaded.

Use rail mounted chocks to secure a railroad car. Also, prevent anyone from moving the rail car while the forklift is working. A blue sign with the word “STOP” attached to the track is one way to signal that the car must not be moved. A special attachment must be used if a forklift is used to open a rail car door.

LOADING AND UNLOADING THE FORKLIFT

Check the load before you pick it up. Is it stable or will parts slide or fall during transit? Secure it as necessary. Do the dimensions and weight of the load fall within the capacity rating of the forklift at the highest elevation and extension you will handle the load? If not, can you break the load into smaller parts?

When you pick up the load:

• Move squarely into position in front of the load.
• Position the forks wide apart to keep the load balanced.
• Drive the forks fully under the load.
• Tilt the mast backward slightly to stabilize the load and lift.

Check the destination before you place the load.

• Is the destination flat and stable, or will the load rock, tilt or lean?
• Never place heavy loads on top of light loads.

When you place the load at its destination:

• Move squarely into position in front of the rack or stack where the load will be placed.
• When ready to place the load, tilt the mast to level. Only tilt forward when the load is over the spot where it will be placed.
• Lower the forks and back away.
• Visually verify that the load is stable.

LEAVING A FORKLIFT UNATTENDED

A forklift is considered to be unattended when it is not in view of the operator or, if it is in view, the operator is 25 feet or more away. If you leave a forklift unattended, lower the forks to the ground. Set the controls to neutral, turn off the power and set the brakes. If the forklift is on an incline, be sure to block the wheels.

IIf you dismount a forklift and stay within 25 feet, you must at least lower the forks to the ground, set the controls to neutral and set the brakes.

This article was excerpted from “The State of Washington Forklift Safety Guide,” which was produced by the Washington State Department of Labor and Industries.