A Defective Forklift Can Kill

A 43 year-old president of an advertising sign company was killed while using a forklift to unload steel tubing from a flatbed trailer. He was driving about 5 miles per hour beside the trailer on a concrete driveway with a 3% grade. The victim turned the forklift behind the trailer. The forklift began to turn over on its side. The victim jumped from the seat toward the driveway. The victim’s head and neck were pinned to the driveway by the forklift’s overhead guard. An inspection of the forklift revealed that the right-side rear axle stop was damaged before the accident and was not restricting forklift lateral sway as it turned. Also, slack in the steering mechanism required the operator to turn the steering wheel slightly more than half a revolution before the wheels started to turn. The forklift was not equipped with a seat belt. 

Pre-use inspection

The forklift must be checked for defects daily — usually by the operator before beginning a shift. Even if you operate a forklift safely, a defect can cause or contribute to a serious accident. Some things to look for are:

 •Is the horn working? Sound the horn at intersections and wherever vision is obstructed.

 • Are there hydraulic leaks in the mast or elsewhere? These could cause slipping hazards or lead to hydraulic failure. 

• Are fuel connections tight and battery terminals covered? Dropping a piece of metal across battery terminals can cause an explosion. 

• Is there a lot of lint, grease, oil or other material on the forklift that could catch on fire?

 • Do sparks or flames come out from the exhaust system? 

• Does the engine show signs of overheating?

• Are tires at proper pressure and free of damage? A tire with low pressure or a tire failure can cause a forklift to tip or fall when a load is high. 

• Do all controls such as lift, lower, and tilt work smoothly? Are they labeled? 

• Is there any deformation or cracks in the forks, mast, overhead guard, or backrest? 

• Are lights operating if used at night or in dark locations? 

• Is steering responsive? A lot of play or hard steering will reduce your control.

 • Do brakes stop smoothly and reliably? Sudden stops can cause tipping.

 • Does the parking brake hold the forklift on an incline?

 • Are seat belts (if equipped) working and accessible? 

• Is the load capacity plate readable?

Any defects that would affect safety must be corrected before the forklift is returned to service. 

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 them up 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, outside of the forklift frame. 

• 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

Failure to secure the truck or trailer with blocks can cause the trailer to move resulting in the forklift falling between the trailer and the dock.

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.

An unsecured dock plate can move over time resulting in a sudden stop of the forklift and loss of the load as the wheels lodge in the space between the dock and the truck bed

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 four 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 of signaling 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. The illustrations below show some common pallet stacking patterns.

• 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. 

• Observe maximum stacking quantities and orientation if printed on cartons. 

• Do you know the load bearing capacity of your rack or storage loft destination? 

• Are rack legs or support members bent or disconnected? The load bearing capacity of a damaged rack is unknown! Wait until the damaged component has been replaced before loading. Block The most common. The upper level may be unstable if not encircled with wire or strapping. Brick Containers are interlocked by turning each level 90 degrees. Pinwheel Used where brick pattern is unstable. Irregular Stacking Patterns Wood strips, plywood or heavy cardboard between layers can help stabilize castings, bags, and other irregular shapes. 17 Revised 04/01/2007 Revised 04/01/2007

• Are racks arranged back to back with a stock behind where you will place the load? Someone may need to be in the next aisle to control access while you place the load. 

• Are wooden stringers or decking laid between front and rear rack beams in good condition? 、

• If you are stacking, are other pallets in the stack in good condition and capable of supporting the load in addition to what they are already supporting? 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, block the wheels. 

If 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.

Lifting and lowering people

Never allow anyone to be lifted while standing on the forks or on a pallet lifted by the forks! If you want to use a forklift to raise an employee to an elevated position, use a platform or structure specifically built for this purpose that meets these conditions:

• The platform must have standard guardrails which include a top rail 36” to 42” above the platform (39” to 45” on a construction site), midrail and toeboard. It must also prevent contact with chains and shear points on the mast. 

• The platform must be securely attached to the forks such as by a clamp or chain. 

• Check with the forklift manufacturer to verify that the hydraulic system will not allow the lift mechanism to drop faster than 135 feet per minute in the event of a system failure. Identify the forklift as approved for use with the platform. 

• Lock or secure the tilt control to prevent the boom from tilting. 

• A forklift operator must be at the normal operating position when lifting and lowering the platform. The operator must be near the forklift while a worker is elevated. 

• Except to inch or maneuver at low speeds, do not move the forklift between two points when a worker is on the platform. Order picker forklifts are designed to allow the operator to be lifted along with the controls to an elevated location. However, if the operator station does not have standard guardrails on all open sides, then the operator must wear a full body harness with lanyard attached to a manufacturer approved anchor.

Fueling/charging

When refueling or charging batteries, observe the following precautions: 

 • Do not smoke or allow any open flames or spark /arc generating equipment in the refueling / charging area. 

• Make sure there is adequate ventilation to disburse fumes. 

• Make sure there is a fire extinguisher nearby. 

• Make sure there is a barrier that protects the pump or charger against vehicle damage.

Liquid Petroleum Gas (LPG) forklifts

• LPG gas is very cold. Wear gloves when changing LPG tanks. Check for leaks before operating.

Gasoline or diesel forklifts

• Turn the engine “OFF” and apply the hand brake before gasoline or diesel refueling. 

• Clean up any spilled fuel before restarting the engine.

Battery operated forklifts

• When charging batteries, keep the battery vent caps in place to prevent electrolyte spray. (Check that the vent caps are not plugged.) 

• Keep the battery compartment open to dissipate heat. 

• Keep tools and other metal objects away from the top of the battery to prevent an arc or explosion due to short circuited terminals. 

• When adding fluid to the battery, wear safety glasses and a face shield for protection against electrolyte splash or spray. 

• Battery charging areas must have a way to flush and neutralize spilled electrolyte. 

• Do not attempt to remove a battery from the forklift unless you have been trained and the charging station is equipped with a hoist designed for this purpose.

• If you do any service to a battery beyond routine charging the employer must supply an eyewash station that can be reached within 10 seconds and that is capable of providing .4 gallons of water per minute for 15 minutes.