How to Reduce Forklift Accidents - Be Safe & Save Lives
Learn how to reduce forklift accidents; effective, affordable lift truck safety training by our experts for all your employees. Stay safe and accident-free.
In order to be able to safely use forklift equipment, you must first understand how a forklift operates, the weight that it is designed to handle and how it must be repaired. These are all critical factors to understand how to reduce forklift accidents. Accidents occur when there is a lack of education and proper training. Learn more by reading below, or contact the experts at Wayco today to get practical, hands-on training!
Forklifts are gaining popularity because of their ability to move large quantities of product, effectively and quickly. They are an essential tool for many businesses across Canada. A top priority should be to create a safe workplace by learning how to reduce forklift accidents. There are key issues that must be addressed and every employee must be aware of risk factors at all times.
OSHA statistics indicate that there are roughly 85 forklift fatalities and 34,900 serious injuries each year, with 42 percent of the forklift fatalities from the operator’s being crushed by a tipping vehicle.
How To Reduce Forklift Accidents
Four of the most common reasons why forklift accidents happen are not having proper training, no pedestrian and worker awareness, driving issues, and loading problems. If these four factors are addressed, the risk of workplace injury will decrease substantially.
1. Get Proper Training
Proper training is one of the best ways to help prevent accidents
Accidents often happen in the workplace due to not enough training or not knowing how to maintain the forklift properly with various safety checks that should be done on a daily basis. To determine if a machine needs servicing, a forklift inspection is essential. Regular inspections can help to prevent accidents and injuries.
OSHA believes that proper operator forklift training can reduce the risk of accidents by 25-30%. If you need to brush up or you need new forklift training, Wayco is able to offer this service. Safety standards not only help to prevent accidents, but they also keep employees healthy and prevent damage to your equipment and inventory.
2. Promote Pedestrian and Worker Awareness
Workers should always be aware of others around them
Pedestrians always have the right-of way, even if they are walking in the path of a forklift. It’s no different than driving a vehicle on a road. Pedestrians cannot always see the lift truck, or hear the forklift, which can result in an accident or injuries. The workplace can control these accidents through better traffic management and awareness.
Employers can create designated walkways or travel ways, and equip the forklift with a blue safety light that projects on the floor in front or behind the approaching forklift’s path, warning pedestrians of its approach and direction. These are just a few things to prevent accidents.
Pedestrian Awareness training covers the basic hazards in the workplace between pedestrians and forklifts.Pedestrians learn to stop, look and listen. You never know when a truck may appear suddenly around a blind corner.
It is also important tor engage in eye contact with the forklift driver before crossing the forklift’s path. Close to 20 percent of all forklift accidents involve a pedestrian being struck by the forklift. It is crucial for communication and alertness to reduce forklift accidents.
3. Address Driving Issues
Safe driving can help reduce accidents and injury to both workers and pedestrians
The most common accident happens from traveling too fast in the wrong conditions. Even experienced drivers can make mistakes if operating in an unsafe manner.
Lift trucks are really heavy and often unstable, and the operator driving the forklift has to drive responsibly. They can not only put themselves at risk, but they can jeopardize the safety of other employees and pedestrians.
Erratic driving, stunt driving, or any horseplay should be reported immediately to a supervisor and the operator should be disciplined.
7% of all forklift accidents are caused by driving off a loading dock and all other accidents are due to traveling at high speeds, improper backing up or parking techniques, turning or braking incorrectly, improper warning, riding with the load elevated and inadequate servicing of the forklift.
To reduce forklift accidents, all potential hazards need to be understood by forklift operators to perform their jobs in a safe and appropriate manner and prevent accidents and injuries.
OSHA collects more than $2 million each year from citations issued to organizations that fail to maintain their forklifts or provide adequate training to their employees.
4. Prevent Loading Problems
Workers must understand the load capacity for the vehicle(s) they use
Each forklift has a manufacturer’s load capacity plate. It determines the maximum weight that a forklift is able to safely carry at a specific load center.
To ensure the weight is distributed properly; it is critical that loads are secured and carefully centered on the forks. If not centred the forklift’s capacity will be reduced and it can tip over easily.
Actually, 14% of forklift accidents or serious crush injuries are caused by rollover, collision or falling loads if the capacity is exceeded.
To reduce forklift accidents, here are some of the loading problems that should be avoided:
Poorly stacked or piled items on the pallet.
Load is too heavy or blocking vision
Exceeding the recommended load limit of your lift truck.
Loads not close to the front wheels to keep lift truck stable
Unstable loads
Carrying a heavy load with the forks too high
Raising or lowering the fork when the lift truck is not stopped
Lifting loads straight up or tilted back slightly
Forks not spaced properly
It may seem like an easy, simple thing to operate a forklift, but if not done properly, significant injuries and damage can occur. If you are not properly trained, contact us and to help you prevent unnecessary risk.
Tip: Load Center is easily calculated by measuring the load to be carried, and dividing by two (providing the load is evenly distributed, and positioned to butt up to the forklift backrest). You will often see a forklift truck’s nominal capacity quoted in a form such as 2,000kg @ 500mm load centre.
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A serious workplace injury or death changes lives forever – for families, friends, communities, and coworkers too. Our training programs will provide you with all the skills and knowledge you need to properly and safely operate a forklift. Start your forklift training today!
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The Importance of Daily Forklift Operator Checks
The importance of daily forklift operator checks are to evaluate whether forklift operators are conducting business in a safe way. Get trained today.
The purpose of daily forklift operator checks is to evaluate whether the forklift operator is conducting their business in a safe way. If you, as a forklift operator, do not take responsibility, to correctly maintain and keep your forklift in a serviceable condition, there is potential to cause accidents, injury or even death. Contact us for your forklift training to learn all the key factors before and after operating a forklift.
The Importance of Daily Forklift Operator Checks
OSHA (Occupational Safety and Health Administration) requires that forklift vehicles have to be inspected at least daily, or after each shift when they have been used around the clock. This inspection helps contribute to a safer working environment and prevent costly lift truck repairs.
A forklift can become a dangerous thing in a workplace for workers, visitors and the people around it. There are lots of things you can do to prevent injuries, such as risk assessments, ongoing operator monitoring, reporting incidents and practical, hands-on training.
However, there is one precaution in particular that you should pay close attention to and is the practice of daily checks. These pre-inspections are very important as they can identify small problems and stop them becoming bigger problems. There are a number of benefits of doing a pre-inspection check; it can reduce your costs, increase uptime, and improve battery life.
When forklift drivers fail to inspect their forklifts prior to use, accidents like this can happen. A 43 year-old man was killed while using a forklift to unload steel tubing from a flatbed trailer.
Turning the forklift behind the trailer, the forklift began to turn over on its side. The driver jumped from the seat toward the driveway where his head and neck were ultimately pinned under the forklift’s overhead guard.
An inspection revealed slack in the steering mechanism that required the driver to turn the steering wheel more than half a revolution before the wheels started to turn and a damaged right-side rear axle stop that didn’t restrict lateral sway as the forklift turned. Tragically, this forklift was not equipped with a seat belt.
A well-maintained forklift is crucial to prevent accidents and you should be reminded about the importance of pre-use inspections.
Before Starting Your Forklift
What specifically are forklift operators to check for? At the beginning of a shift, or just prior to use, a operator must perform two checks: (1) visual check and (2) operational check. Regardless of how often the lifting equipment is used or how it is performing, the inspection still needs to be done.
Forklifts must be kept safe and fit for every operator because it saves lives, prevents injury, and protects equipment and inventory from expensive damage. Employers should take steps to ensure that inspections are not overlooked and that operators are trained and competent to inspect the equipment.
Here are seven key considerations for you to look out for when tackling to improve safety with pre-shift forklift inspections.
Keep it simple – Forklift operators need to know how to check the general working parts of the truck for signs of damage or wear.
Check every time – If anything has gone wrong from the previous day or shift, check all faults have been rectified.
Understand the law – If you do not carry out a pre-use inspection, you are breaking the law by failing your duty of care for yourself and to others.
Be specific – a specific pre-shift sheet should be used for every type of truck and cover all the major parts that should be checked.
Manage and supervise – It is vitally important that managers and supervisors understand pre-use checks themselves in order to assess whether the correct procedures are being followed.
Provide training – Suitable training should be provided to ensure operators have these essential skills.
Stay safe – Remember the basic skills and operate the forklift safely, even when doing a pre-use check.
Forklift pre-shift inspections only take a few minutes to ensure your safety, the safety of the people around you and the safety of your forklift.
Here Is What an Operator Should Look
for Carrying Out Their Visual Daily (Circle) Checks:
The first and most important rule to follow with forklifts is – get trained! Having a daily inspection checklist as part of your routine will create a safer workplace and will save you money.
A forklift operator should run through the entirety of this checklist and log their data; this will reduce the guesswork of what the forklift is ready to do. It can also reduce expenses through avoidable repairs.
The best way to start your inspection is to approach it from top down, beginning with the overhead guard. Ge into the same routine as this will provide you with a sense of structure and familiarity.
What should an operator inspect during the visual pre-use check?
General condition and cleanliness – should be free of lint, excess oil, and grease
Floor – clear of objects that could cause an accident.
Overhead – no obstructions—interfering with safe forklift usage.
Nearby objects to avoid as you drive away.
Fire extinguisher – present and charged.
Engine oil level, fuel level, radiator water level (LPG, gas and diesel forklifts) are good.
Battery – fully charged; no exposed wires; plug connections not loose, worn or dirty; vent caps not clogged; electrolyte levels in cells is adequate, and is secured in place by hold downs or brackets.
Bolts, nuts, guards, chains, or hydraulic hose reels are not damaged, missing or loose.
Wheels and tires – check for wear, damage, and air pressure, if pneumatic tires.
Forks – forks not bent; no cracks present; positioning latches in good working condition; carriage teeth not broken, chipped or worn.
Chain anchor pins – not worn, loose or bent.
Fluid leaks – no damp spots or drips.
Hoses – held securely; not loose, crimped, worn or rubbing.
Horn – working and loud enough to be heard in the working environment; other warning devices operational.
Seat belt and/or operator restraint device (if equipped) – belts and restraints work properly; no visible wear or damage; anchors, buckles, etc. function properly.
Overhead guard – no damaged areas.
Every forklift is different with different parts and therefore they need to be checked during a walk around inspection.
The operator should refer to the Operation & Maintenance manual for diagrams and information on the particular forklift that is being inspected. Use your senses of sound, sight, smell and touch. Ask us about our pre-shift checklist.
What an Operator Needs to Check During the Pre-start Operational Check:
When it comes to operating a forklift that can handle tons of loads, you need to prevent mechanical or operational failures by conducting a physical operational check.
Maintaining a safe workplace is key to business success. After completing the pre-operation inspection, operators should conduct an operational inspection with the engine running. The forklift can be placed into service once it has passed all the operational checks.
The OHSA Reg: 1910.178(q)(7) states any problems with the inspection should be recorded on the appropriate documents and reported to a supervisor immediately.
Foot Brake – pedal holds, unit stops smoothly.
Parking Brake – holds against slight acceleration.
Lift Mechanism – operates smoothly (check by raising forks to max height then lowering forks).
Tilt Mechanism – moves smoothly, holds (check by tilting mast all the way forward and backward).
Deadman Seat Brake – holds when operator rises from seat.
Clutch and Gearshift – shifts smoothly with no jumping or jerking.
Dash Control Panel – all lights and gauges are operational.
Steering – moves smoothly.
Cylinders and Hoses – not leaking after above checks.
Listen for any unusual sounds or noises.
Remember that the operational check must be carried out by a competent trained person . If the operator notes any of these conditions while driving, the operator must stop, park the vehicle and get assistance.
After Starting The Forklift:
Once you have completed the initial check (Before Starting The Forklift) you’re not done just yet. It’s extremely important to practice safe driving, here are just a few rules to follow when operating your forklift.
Always look in all directions before proceeding.
Always look in the direction of travel. If the load blocks your view, travel in reverse. Keep a clear view.
Maintain a safe distance, safe speed, and keep the truck in control at all times.
Yield the right of way to pedestrians
Do not pass other trucks in the same direction.
Absolutely no stunt driving or horseplay.
Beware of the environment conditions – slow down for wet and slippery floors.
Never carry passengers.
Keep arms and legs inside the confines of your vehicle.
Be especially careful on loading docks; stay away from the edge.
Stay Safer On The Job With Forklift Hub!
A serious workplace injury or death changes lives forever – for families, friends, communities, and coworkers too. Our training programs will provide you with all the skills and knowledge you need to properly and safely operate a forklift. Start your forklift training today!
Forklift Safety Checklist
Learn to stay safer on the job with the help from our forklift safety checklist! This extensive checklist provides information on safe operations and precautions while using a forklift.
Did you know that forklifts often weigh more than 3 tonnes and travel around 15km/h. Forklifts are everyday equipment in factories, warehouses and construction sites, but many people do not realize they can be potentially dangerous. Safety is no accident. That is why it is a good idea to have a forklift safety checklist and follow it carefully. If you have any question about implementing and following your own forklift safety checklist, contact us today. We’d love to help you.
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Forklift Safety Checklist
Forklifts pose a potential threat to workers everyday. Operating a forklift should always be done properly to ensure the safe handling of products and most importantly to ensure the safety of the employees. Never hand over the forklift keys before knowing that the operator knows all of the important guidelines for using a forklift.
🗸 Examine Forklifts Before Every Shift
It is important the forklift operator performs a Pre shift Operator Inspection before every shift and thoroughly identify any hazards in the workplace area before starting. Inform your supervisor immediately of any identified issues, problems, questions or concerns.
If any are discovered then the truck should be removed from service. Keep an operator forklift safety checklist in a designated area where the operator has easy access to it.
🗸 Never Leave Keys in Forklift Unattended
A forklift is a dangerous tool if the operator is not trained to use it. Leaving keys in an unattended forklift is illegal even without the actual occurrence of an accident. The truck should be turned off, and the key should be removed from the ignition and stored in its proper location. Only a trained certified operator can be entrusted with heavy machinery.
🗸 Starting And Stopping your forklift
After identifying and addressing all the hazards, you should follow these safety practices:
Getting on and off properly: Getting on and off your forklift the proper way ensures that the operator is stable enough to avoid falling and prevent any injuries.
Footwear: Wearing the appropriate shoes will give you a firm grip and solid footing when mounting or dismounting the forklift.
Seat belt: A seat belt is mandatory; the law requires you to wear the seat belt at all times when operating a forklift.
Lower forks: Another key factor to safe forklift operation is that the forks should be lowered to the floor whenever the vehicle is parked.
Use Designated Paths: Follow the company rules and regulations, always take the safest or designated path in the warehouse.
Stopping and Parking: When stopping your forklift lower the forks when left unattended. Place controls in neutral and shut off power. Always use the parking brake and block wheels when parked on an incline. Park on a level surface and in authorized area. Remove the key from the ignition. Improper parked forklift runs the risk of rolling into pedestrians or being hit.
🗸 Driving Safety
While driving, make sure you always keep an eye out for other people around you, especially those on foot. Pedestrian Awareness training should cover the basic hazards related to forklifts, and the rules that need to be followed. Important rules to remember include:
√ Watch for blind spots and drive slowly
√ Follow all signs and regulations
√ Never carrying passengers
√ Do not drive with forks too high
√Alert others of your coming with a horn or your voice
√ Never drive trucks up to anyone standing in front of a bench or other fixed object
√ Always check carefully before turning or backing up the vehicle
√ Avoid running over loose objects
Always maintain a safe distance, never placing arms outside the running lines of the truck. Make sure there is enough room for the forklift to clear from lights, pipes or sprinkler systems. It is also important to always yield to all emergency vehicles in the plant.
🗸 Steering and Turning Safety
Think it can’t be that much different than driving a car? Think again. For one thing, forklifts are a lot more top-heavy than cars; especially when their forks are extended up the mast. Cars and trucks use their front wheels to steer.
Forklifts can turn in a very tight circle because it steers with the rear wheels. What this means is that with a forklift the front wheels are used to support most of the load with the forklift’s rear end swinging in a circle around the front wheel.
So remember a forklift’s rear steering makes it difficult to stop a it quickly. An essential part of staying safe, is recognizing the importance of not driving fast or rounding corners too quickly.
It could be extremely dangerous, tipping over and the risk of injuring a pedestrian as well as yourself. Even the expert forklift drivers find it difficult to swerve and still maintain control of the forklift.
The whole forklift can tip over with one wrong move. You should fully stop before changing directions and slow down before you turn. Do not turn with raised forks or if you are on a grade. The more experience you have steering a forklift the easier it becomes; it’s like riding a bike.
🗸 Safe and Smooth loading and Unloading
The most common forklift accident that happens in the workplace occurs by tumbling loads in which operators were not properly secured to their seat.
A forklift tipping can lead to product loss, damaged equipment, and potential injury to the forklift operator. Only handle stable loads, and never exceed the loaded capacity of the truck. The best way to ensure that a tip-over will never happen is to have the operators educated in the safety aspects of operating forklifts.
Driving on inclines: Driving on an incline requires extra caution. Place loads back by the mast; that is where it is most stable. Direct your forklift forward when driving up ramps, but go downhill in reverse. Do not turn forklift or load / unload on the ramp. Make sure dockboards have been properly secured before they are driven over.
Visibility: Always make sure your path is clear and watch for the dangerous areas that are clearly marked. Have a good view of and easy access to the location or rack where you must position your load.
Operate the forklift in reverse to improve visibility and operation control if your load obstructs your view. Enlist the assistance of a helper to guide or lookout between obstacles and people. Headlights, mirrors and other visual aids should be equipped on a forklift for safety.
Loading/Unloading: Never load trucks beyond the allowed approved capacity. The load must be strapped in place and balanced on both forks before moving the vehicle.
Make sure that all decaying, warped or otherwise damaged skids, pallets or wrapping material is clear and free from your load. When loading or unloading shelves, ensure the storage shelves/racks, and dock plate are properly secured.
Do not tow or push with a forklift. Drive carefully and slowly over the plate and do not spin wheels. Turn the forklift slowly into position, squaring it up to the drop-off location.
🗸 Tip Over Safety
Forklifts usually either tip forward or to the side; this happens for different reasons. The most important thing to remember is that the center of gravity should always stay positioned inside the wheel base; too far forward or too far left or right increases the risk of a tip over. Here are a few more reasons why a tip over can happen causing serious injury:
√ Operator exceeds the load capacity of the forklift
√ Extreme speed when turning the lift
√ Turning on an incline or uneven surface
√ Lift gets too close to an edge on the floor traveling with the load too high
√ Turning or braking too quickly with a raised load
√ Unstable load or oddly shaped load that is too tall or wide
Driving into a pothole, turning a corner, carrying an uneven load or driving on a sloped surface can cause the forklift to lose proper balance and tip over.
If a tip over does occur, do not try to jump out of the vehicle, stay in the forklift and hold on to the steering wheel.
Most people want to jump and get out of the way, however, a forklift will continue into a roll, usually crushing or pinning the worker underneath. Brace your feet and lean forward. Lean away for the side of impact.
A few more important safety pointers to help your forklift from tipping over:
When traveling on a sloped surface, ensure the load is facing uphill
Position the forks no higher than 4-6 inches above the ground when traveling
When lowering or picking up a load, tilt the mast forward
When traveling, the load should be tilted backwards
Never brake suddenly with a raised load
Make sure you have enough space when traveling underneath overhead obstructions or through a doorway
Fork load should not be beyond the maximum capacity of the truck
Stay Safe On The Job With Forklift Hub!
For every type of forklift, the rules are simple: follow the safety tips, get properly trained, become educated about the safety of the equipment and reduce risks associated with forklift operation.
You should always observe the workplace and identify any workplace hazards that might affect the forklift. Employers should establish safe workplace practices for all work involving forklifts. Putting these forklift safety tips into effect at your company should give you and your fellow co-workers a better chance of going home safely at the end of the day.
Contact us today to learn more about our safety training.
5 Elements of Forklift Safety
To help get you started on your road to safety, here are 5 elements of forklift safety. The most important thing to notice is that these elements don’t cost much more than your time and determination with proper forklift training!
In many industries today, it isn’t surprising that forklift truck safety isn’t a priority for most managers and supervisors. According to OSHA, 96,785 is the number of injuries caused every year (non-serious, serious, and fatal) due to improper training or sheer carelessness on the job.
In the United States, the number is 855,900, meaning that each year more than 1 in 10 forklifts are involved in an accident (assuming 1 accident per forklift).
These accidents change many lives forever. That is why in 2018, we are encouraging companies to make forklift training a mandatory part of their operations and provide all proper safety information to all of their employees. Take control of your training process and Contact us now!
5 Elements of Forklift Safety
To help get you started on your road to safety, here are 5 elements of forklift safety. The most important thing to notice is that these elements don’t cost much more than your time and determination.
1. Train For Safety
A commitment to safety begins with proper training. Forklift drivers and their employers are governed by federal and provincial safety standards.
There is no official “license” to obtain in order to operate a forklift, but drivers must have proof that they have received training that meets government standards. Attend a forklift operator training course that meets standards set out by the Canadian Standards Association (CSA) and the Ontario Ministry of Labour (MOL) for forklift or lift truck operator training.
There will be an in-class theoretical component and a hands-on practical component. Once completed successfully, you will receive written confirmation in the form of a certificate. The CSA also recommends that you need to complete a practical retraining course every 18 months and a comprehensive classroom and practical re-certification every 3 years.
Most companies recognize the importance of ‘basic’ operator training. But this alone doesn’t give your operators the tools, skills, and knowledge necessary to work as safely and efficiently as possible, in their role, with their equipment, and in their working environment.
A forklift is dangerous; this is the main reason why safety training should be taken seriously. Untrained operators don’t fully understand how to operate equipment, and they can overlook important safety precautions. Accidents are much more expensive than spending money for training: Why? Forklift training benefits the company not just the worker who operates the forklift.
Damage due to inexperienced drivers can be costly, cause injuries to operators and pedestrians, cause downtime, and cause loss of life.
Forklift training will also deal with the most common reasons and situations in which accidents occur and how to avoid these risks and safely operate the forklift.
By learning how to avoid the most common situations and behaviours that result in accidents, you will be able to minimize those risks so that the forklift can be used as the tool it is meant to be, saving backbreaking labour and actually making the workplace safer.
2. Perform Checkups
Getting into the habit of regularly inspecting (circle check) all equipment is a simple but important preventative measure, and should be part of every operator’s daily pre-shift routine.
Performing a “circle check” reduces the chance of equipment being operated in an unsafe condition. Pre-Checkups will make it easier to spot and deal with maintenance issues early before they become more serious causing downtime, equipment damage or extensive repairs.
In its 29 CFR 1910.178 standard language, OSHA states that forklifts must be inspected either daily or after each shift in cases where vehicles are in round-the-clock use. Checkpoints should include seat belts, tires, lights, horns, brakes, backup alarms and fluid levels, as well as the moving and load-supporting parts of the forklift.
You might have multiple employees using a single forklift within your workplace, so it is important that you familiarize yourself with the new forklift or just ensure the forklift is up to scratch since its last use.
A useful tool is a pre-inspection checklist. Implementing the use of a paper checklist system reminds the operator to regularly perform all pre-shift checks, ensure that problems are documented and communicated to supervisors, and help pinpoint when and how changes in the condition of the equipment occurred.
Next, do a quick overview of the work environment conditions. Is there any evidence of any fluid leaks? Is the floor and surrounding area clear of obstruction? Some important points you need to take extra care of are checking the data plate for capacities ( safe working load), load center, and mast full height (MFH).
A pre-operational inspection of equipment, however, is NOT the same as training to operate the equipment. Do not operate or work with equipment unless you have been properly trained to do so.
Proper pre-operation inspection protocols are important in helping avoid workplace damage and injury, and they should not be difficult to manage when using our pre-operation checklog book to ensure inspections are being done daily.
3. Know The Machinery & The Rules
Operating a forklift is serious business, so it is important to be more proactive in how you operate it. If you are not careful, you could really hurt yourself, hurt other people, or you could ruin a product.
There’s a lot that can happen just by your simple lapse of judgment. In many ways driving a forklift is basically like driving a vehicle on the road. Treat the forklift with respect, as well as the pedestrians walking around you. If you do this you and everyone else will be safe.
Even though lift trucks and personal vehicles share some similarities, they ultimately are quite different. The following are ways that a lift truck varies from a personal vehicle:
Open structure, driver completely exposed
Weights ranging from 9,000 to 30,000 pounds, with rough-terrain lift trucks at the heavier end
Travelling speeds of less than 20 mph, closer to a walking pace
Three-point forklift stability vs Four points car stability
More prone to tipping overloaded or not – and varying stability
Tighter turning radius for operating in tight spots
Rear wheel steering, tail swings wider than a car
Another important forklift safety practice which is overlooked quite often is knowing your machine.
Just because you know how to drive your forklift doesn’t mean you know how to operate another. Different brands or models function differently.
Components such as pedals, switches, and steering can vary from one type of forklift to the next. In addition, workplace conditions like rough surfaces, obstructions and closed environments can present hazardous conditions that make it critical for operators to get proper safety training.
Always be aware of your surroundings and the machinery you are operating. There are many options to increase visibility including better processes, better lighting, safety equipment and more.
Operators need to be aware of and make eye contact with, pedestrians or other workers. Here are some other measures you should take to increase drivers visibility:
Keep a clear view, and operate in reverse if it improves visibility, except when on ramps.
Always look in the direction of travel.
If visibility is poor, do not continue driving.
Reduce aisle and dock clutter.
Use spotters or aids such as rear-view mirrors to boost visibility.
Pay attention to pedestrians, and warning sounds.
Get properly trained on forklift and warehouse safety procedures.
Make sure you can see the racking clearly in which you are positioning your load.
Remember the rules and Don’t take chances with your safety. Knowing and understanding your forklifts will determine the level of safety within your workplace.
4. Understand The “Stability Triangle”
In forklift training, safety is the key, however. no matter what is being taught, there are various topics to learn about, like the stability triangle. Load weight, weight distribution, size, shape, and position are key factors affecting the stability of the forklift.
One of the hardest things for lift truck operators to grasp in training is the importance of maintaining their center of gravity within their stability triangle.
In a few words, a forklift has a three-point suspension system. It is found over the two front load wheels, as well as the back mid-point between the rear wheel. If you draw a line between the two front tires to the pivot point on the rear axle and back again you get the forklift stability triangle.
When you raise or lower a load, make quick turns, and tilt the mast, the center of gravity shifts inside the stability triangle. The center of gravity must remain inside this triangle.
I’ve just mentioned the top point of the pyramid is located just above the operator’s head. Watch this video to fully understand the stability triangle.
All forklifts have a rated capacity – most are rated at a 24-inch load center, which is the center of standard 48-inch-long forks. The rated capacity drops as you move a load out from the load center. As a rule of thumb, for every inch you move a load forward from the load center, the capacity of the forklift will drop a few hundred pounds.
You should always travel with your forks down low because you have more room for your center of gravity to move.
When you have the forks high, it’s called the triangle of stability which refers to the balance of weight.
Factors such as heavy and unbalanced loads, driving on sloping or uneven terrain, or turning with elevated loads can result in the center of gravity moving outside of the triangle. The result can be catastrophic. Another important safety rule to remember is to be sure to wear your seatbelt at all times.
To take a step back, one of the greatest risks that a lift truck operator faces is a tip-over. Tipovers are the cause of about 100 deaths, 34,900 serious injuries and 61,800 minor injuries of lift truck fatalities, according to one source.
In 2010, OSHA identified about 110 workplace fatalities where the lift truck was identified as either the primary or a secondary source of the accident. As mentioned above, a tipover can occur when the center of gravity moves outside of the stability triangle.
IF YOUR LIFT TRUCK STARTS TO TIP OVER REMEMBER THESE CRITICAL STEPS:
Do not jump off the forklift even if it begins to tip over
Firmly hold on to the steering wheel
Brace your feet
Lean away from impact
Lean forward
Prior to operating a forklift, it is critically important for forklift operators to be both fully trained and qualified. They should thoroughly understand the safety instructions in their Operations and Maintenance Manuals so they can completely understand how to avoid forklift tip-overs as well as actions to take if one occurs.
5. Know About The Load Basics
What’s so hard about lifting a load? It may seem simple to pick up a load, yet if not done properly, injury and damage can occur. A forklift must be maneuverable, however when carrying loads, they become unstable.
It is important for a forklift operator to have a clear understanding of their forklift’s load capacity. As more forklift options and attachments become available, it reduces the load capacity limitations.
The attachment has a weight of its own that will eat up some of your unit’s capacity. A load capacity is determined as the maximum weight that a forklift is able to safely carry at a specified load center. The load limit is shown on the data plate of the lift truck; do not exceed the maximum load limit.
Forklift operators also need to be aware of the load they are moving. The weight, shape and size affect the load center. If you are lifting a more bulky or deeper item, the load centre will increase.
Operators need to check loads before picking them up with the forks, ensuring the load’s stability and dimensions will allow for safe transport. Some useful tips you should always keep in the back of your mind when loading include:
Always approach the load slowly and carefully
Stop 8-12 inches in front of the load
Make sure the truck is placed squarely in front of the load
Make sure the forks are at the correct height for lifting the load
Set the direction control to neutral
Never raise or lower the forks unless the forklift is stopped and the brake is set
Before raising the load, make sure there’s enough overhead clearance. Your vision can be blocked after the load is elevated.
Use the inching pedal to creep the load to the stack.
To make sure that the load is stable, heavy objects should be placed at the bottom of the load and at the rear of the load. You should secure the load if there is any chance of objects falling off and the load should not extend beyond the backrest of the carriage.
Operators should never drive forward with forks raised and should lift them off the ground a few inches before proceeding. A load that’s too heavy can raise the forklift’s rear off the ground and create a safety hazard. Also driving too fast may cause the forks to strike something and tip the load over or cause the forklift to suddenly stop.
Make sure you have clear visibility of other traffic, pedestrians, and people not involved when loading and unloading. Machinery can seriously hurt people.
An important note, if you have the attachment changed, or add a new attachment you need to remember to ensure your truck’s data plate is accurate.
Need Forklift Training Kitchener?
Get Forklift training in Kitchener with Wayco! Learn more about our various forklift training classes, such as new operator training, refresher training, and more!
Forklift Training Kitchener - In this article we will discuss the forklift training courses Wayco provides in the Kitchener - Waterloo region. Wayco has been keeping people safe across Ontario for 20 years.
We specialize in providing training to experienced individuals or groups who wish to enhance their current skills and to those who are new and need to obtain certification for a new career.
We are a reliable and reputable company that sets high standards and offers superior training. We strive every day to provide our customers with excellence. If you are interested, let's talk.
Training Courses
The following are some of the options for safety training we provide:
Forklift Operator Training
Forklift Classification Overview:
Forklift Operator training is for new forklift operators and forklift operators who need to be renewed. With so many different types of forklifts, you will need to choose the right equipment for your application.
New Operator Forklift Training
Our New Forklift Operator course is designed for individuals with little or no previous lift truck experience. Our comprehensive program includes a written and practical skill assessment to validate training competencies.
We will provides students with the most current legislative information including the new CSA-B335-15 standard changes. This course can be conducted at your company’s location or at our training center.
Course content is delivered through multimedia presentations and interactive discussion, then reinforced through workbooks and supplementary handouts. Participants will receive a certificate upon successful completion of this course.
Training Topics:
Lift truck (forklift) hazards
Lift truck (forklift) design and classifications
Pre-operational checks (theory and practical)
Standards, regulations and responsibilities
Fuel Sources
Stability
Safe operating procedures
Operator Refresher Forklift Training
The Operator Refresher Forklift Training course will enhance and refresh your forklift operation skills, support the importance of maintaining safety techniques and adhere to driving and operating rules, regulations and guidelines for increased safety and productivity.
This course as well as the new operator course is split into equal parts, hands-on practical training as well as classroom instruction.
If you have previously taken our Forklift Training certification course or training through another qualified provider and need to re-certify, please contact our Operator Training department for course availability.
Forklift operators are required to attend refresher training every 3 years as per CSA legislation B335-15.If you took your training at Wayco, we keep track of your record and will notify you prior to your renewal date.
OHSA needs a written record which includes the name of the operator, dates of the training, classification and the name of the trainer. No worries if you have misplaced or lost your certificate, Wayco can provide a new copy. Our certificates are valid for 3 years anywhere in Ontario.
Elevated Work Platform Training
*Note - This is NOT a replacement for the required Working At Heights
training course
Wondering if you need or would benefit from aerial lift training? While this course is known simply as the Aerial Lift Training, it is actually a comprehensive evaluation of many different hoisting mechanisms such as Elevated Working Platforms, Genie Boom, Scissor Lifts, Man Lifts, Bucket Lifts and Boom lifts.
Aerial Platforms are ideal equipment to get a worker to a place that would never otherwise be safely reached by a ladder or other ordinary means. It allows people to work in high elevations from retail stores to construction sites and warehouses. However, the versatility and safety factors incorporated into these devices allow them to be utilized in almost any environment.
Our Elevated Working Platform training’s purpose is to promote the safe use, inspection and operation of aerial platforms and hazards associated with the use of such equipment.
We will cover responsibilities, devices, and operating controls, personal protective equipment, hazards as well as rescue and operator safety. Depending on your workplace and training requirements, you may receive training for all or just some of the various types of aerial lifts.
Is your group small? We can accommodate individuals as well as group classes. Allow your company greater flexibility to choose training either at your site or ours. Ask our expert forklift Instructor for schedule times.
Aerial work platforms are becoming more popular as they offer a safer way to work at heights. However, it is not a replacement for Working At Heights training. It does not replace the required Working At Heights training course for those working on construction projects.
Pedestrian Awareness
Pedestrians can protect themselves when working near forklifts by using their senses – and their common sense! Our basic Pedestrian awareness training is not just for forklift operators, but also for non-operators such as visitors, office staff or sales people who may venture into the warehouse or yard.
Pedestrian safety is not an issue to be overlooked. Close to 20 percent of all forklift accidents involve a pedestrian being struck by a forklift. Accidents pedestrians and forklifts rarely occur, but when they do, the injuries are almost always serious.
This course will develop skills and knowledge to reduce pedestrian crashes and create a more sustainable pedestrian safety program with training in traffic management, safety equipment and training for pedestrians.
Many employers have established traffic management plans designed to keep pedestrians separate from powered lift traffic, but many programs fall short in providing information, instruction, and supervision for the protection of workers.
People come into proximity with industrial trucks during the course of their work day. Some basic steps should be taken to ensure their safety. Pedestrian/forklift accidents often occur in situations where the pedestrian has been ignorant of safety precautions, or alternatively when the pedestrian has become complacent through frequent interaction with forklifts.
To avoid putting yourself at risk, our program will go through basic steps to avoid common situations like the pedestrian did not see the lift truck, the pedestrian came too close, or the pedestrian did not hear the lift truck. Both drivers and pedestrians must learn to listen and look for warning signs; communication and alertness are crucial
Propane Handling
Do you smell rotten eggs, a skunk’s spray, or a dead animal? It may be propane. Propane has a strong unpleasant smell. The smell is added deliberately by manufactures to help alert customers to propane leaks, which can create a safety hazard.
Can you tell if a propane tank is leaking? Three ways to inspect for a propane leak is by smell (a distinct odor), sound (hissing noise indicates propane is escaping) and sight (frost can sometimes be seen in the area of a leak).
Do you know the proper technique used to change a propane tank? All participants will learn to change a propane tank on a forklift in a competent manner. Our propane cylinder handling course will teach the basics of safely handling of liquid 33lb propane cylinder tanks.
You will learn the correct steps to safe and proper use, exchanging, storage along with inspection of cylinders and how to deal and handle emergency situations. Understanding of the way the chemicals work and how propane is created will ensure a safer workplace.
We will also give you a review of legal requirements and penalties relating to propane compliances. Trained personnel should use personal protective equipment (PPE) when exchanging propane cylinders which includes proper gloves and eye protection.
Personnel that have not been appropriately trained should never attempt to exchange a propane cylinder, and must defer to co-workers with appropriate training.
Since propane-fueled forklifts are heavily used in manufacturing plants, it’s crucial that appropriate training and safety are addressed with regard to propane cylinder exchange.
The key to safety is in proper use and handling which can make propane one of the safest fuels on the market. Propane is non-toxic, lead-free, and has extremely low levels of sulphur
You can combine our forklift training with the forklift propane cylinder safety training course. You can learn how to change a propane tank on a propane powered lift truck.
WHMIS Training
It’s Official! The NEw WHMIS Regulations are now in effect!
WHMIS is a short form for Workplace Hazardous Materials Information System. It is a comprehensive plan for providing information on the safe use of hazardous materials used in Canadian workplaces. Information is provided by means of product labels, material safety data sheets (MSDS), and worker education programs.
On July 1, 2016 the Ontario government amended the Occupational Health and Safety Act and WHMIS Regulation 860 to officially include the new chemical labeling standards that are part of the Globally Harmonized System of Classification and labelling of Chemicals (GHS).
What does this mean for you?
In the WHMIS training course, you will be introduced a new classification rules, all the new Globally Harmonized System of Classification and Labelling of Chemicals (GHS), rules, and label requirements and formats for material safety data sheets which are built on the existing WHMIS 1988. An Overview of hazard groups and classes will make our workplaces safer and more productive.
You will learn to understand labels, recognize the pictograms (symbols), and understand the hazards that they represent. You will be trained on product specific procedures for safe use, storage, handling and disposal of a hazardous product and what to do in case of an emergency situation.
Employers must still complete transition to GHS WHMIS by the original December 1, 2018 deadline. Equally important, employers are still legally required to meet general and workplace-specific WHMIS training obligations. In fact, during the transition period, they must train workers in both original WHMIS and GHS WHMIS.
Definitions
GHS – stands for the Globally Harmonized System of Classification and Labelling of Chemicals. GHS defines and classifies the hazards of chemical products, and communicates health and safety information on labels and safety data sheets
MSD – A Material Safety Data Sheet (MSDS) is a document that contains information on the potential hazards (health, fire, reactivity and environmental) and how to work safely with the chemical product. An MSDS is prepared by the supplier or manufacturer of the material
Lockout / Tagout Training
Lockout-tagout (LOTO) or lock and tag is a safety procedure which is used in industry and research settings to ensure that dangerous machines energy sources are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work.
The proper development and implementation of specifically designed lockout procedures are essential in reducing workplace accidents, injuries, and death.
There are many types of potentially hazardous energy including, electrical, thermal, chemical, pneumatic, hydraulic, mechanical and gravitational energy. All such forms of energy must be locked out, blocked or released to ensure that machinery or equipment does not turn on or move during installation, repair or maintenance.
An employer shall provide information, instruction and supervision to workers on proper lockout procedures for each piece of equipment they will be operating. Failure to control the release of hazardous energy while servicing and maintaining equipment has the potential to cause some of the most severe injuries in the workplace.
All authorized employees who service or maintain equipment, as well as equipment operators and any other affected employees who work in the area where lockout tag out is being performed are required to take this training to meet OHS compliance requirements for lock out tag out.
Additionally temporary personnel as well as outside service and contractor personnel must also be trained in hazardous energy control.
Specific Steps
To shut down, isolate, block, & secure machine.
Safely place, remove, & transfer of Lockout / Tagout devices
To test machine & verify energy is Locked out.
Identify responsible person for Lockout / tagout
Who is responsible for the lockout program?
Each party in the workplace has a responsibility in the lockout program.
We recommend that you should renew your training every 3 years
Forklift Training Kitchener - Work With Wayco Today!
We offer practical, hands-on training to those in the Kitchener area. To learn more about our training program, visit our training page, or contact us now!
I have used Wayco twice, and both times I experienced excellent customer service . They had the right forklift for my needs at a reasonable price. I will be using their services in the future and recommend you do as well.
~Gabe, Google Reviews
Forklift Battery Not Holding a Charge – What To Do
Talk to the leader in forklift battery care; learn how to properly look after your battery to extend its life. Join Wayco's battery care program today!
1. Is Your Charger Working?
FIRST THINGS FIRST! ARE YOU CERTAIN YOU CHARGED YOUR BATTERY PROPERLY?
Did you plug the battery into the battery charger or did you plug the battery charger into the truck by accident instead of the battery?
IF YOU CHARGED IT CORRECTLY AND IT IS STILL NOT HOLDING A CHARGE YOU NEED SOMEBODY TO COME AND INSPECT THE BATTERY TO DETERMINE THE PROBLEM. CONTACT US VIA THE BUTTON BELOW TO HAVE US COME CHECK ON IT TODAY!
Did you know that a forklift battery is like rechargeable battery; it has a finite lifespan! Chances are your battery is going to give you problems at some point in time. Your battery lifespan depends on you and your application.
The frequency and amount of use in which the battery has been charged will impact the lifespan and will help you get the most out of your investment. There are many ways a battery can fail, that can be catastrophic or unrecoverable. If your forklift battery is no longer holding charge, Get in Touch with Wayco for servicing. We provide a forklift BATTERY CARE program.
battery not holding charge?
Forklift batteries are much the same as the lead acid batteries seen in cars, although forklift batteries are a lot heavier, larger and more difficult to repair or refurbish. Forklift batteries are deep-cycle batteries and for this reason they can be discharged to lower levels without causing damage.
There are a number of steps that are very important to get the most life out of your battery, like cleaning, replacing fluids and removing sulfation. These can be done by the worker but refurbishing the battery is best left for a professional who has experience.
Other Common Problems Associated with a Forklift Battery
Forklift batteries are very expensive and are often replaced far too soon because of improper care and neglect. Below is a list of common problems associated with forklift batteries that occur over time.
2. Short Circuit
A common type of short circuit occurs when the positive and negative terminals of a battery are connected with a low-resistance conductor, like a wire. With a low resistance in the connection, a high current will flow, causing the delivery of a large amount of energy in a short period of time.
A “shorted” lead acid battery has the capability of delivering an extremely high current, 100 to 1000 times the typical discharge current used in most applications. The following are signs that your forklift battery has a short circuit.
Very low cell voltage and specific gravity during recharging and discharging
Low gassing while charging
Extreme rise of electrolyte temperature during charging phase
Fast drop of gravity after charging
3. Sulfation
Sulfation, a build-up of lead sulfate crystals, is the number one cause of early failures of lead-acid, sealed AGM or flooded (wet cell-filler caps) batteries. Sulfation is the accumulation of a crystalline form of lead sulfate on the plates of lead–acid storage batteries.
A sulfated battery can lead to loss of cranking power or longer charging times. Sulfation can be avoided if the battery is fully recharged immediately after a discharge cycle.
The lead sulfate crystals are broken down (more or less successfully) in the charge cycle. Sometimes some crystals remain, or sometimes a battery is left partially discharged where the crystals of lead sulfate harden, and reduce the capacity of the battery to be charged. This is what desulfation is about.
While charging, the voltage and electrolyte temperature are much higher than the standard
Gassing is accelerated from charging and the gravity does not rise to normal
Voltage drops quickly while discharging
In some extreme cases, plates may become whitened
4. Excessive self discharging
Self–discharge is a phenomenon in batteries in which internal chemical reactions reduce the stored charge of the forklift battery without any connection between the electrodes.
Self–discharge decreases the shelf life of batteries and causes them to initially have less than a full charge when actually put to use. Self discharge is caused from improper handling. Self discharge can be thought of as energy leaking from your battery which leaks about 5% of capacity per month.
At higher temperatures, the rate typically doubles, so store batteries in a cool place when possible. Remember to always wear PPE (Personal Protective Equipment) when working on batteries.
Quick drop in gravity after charging
Charging capacity of battery significantly reduced
If your battery is no longer working, and you can’t fix it, call us now for an inspection!
Important Forklift Battery Facts
An important part of keeping your warehouse operations running smoothly is proper maintenance of your forklift batteries. When a lift truck battery is down, that usually means one of your forklifts is down and you are losing productivity. First here are some facts about forklift batteries:
A maintained, fully charged battery will provide about six hours of use, equal to an eight-hour shift with breaks included.
Batteries have a lifespan of approximately 1,500 cycles lasting up to 5 years. Each charge takes a cycle out of a battery.
Mismatched batteries and chargers can cause major damage to the battery and the forklift.
Batteries must have adequate water. Typically, they need water added after five to ten charges, and only after they have been fully charged, to prevent a boil over.
“Remember, the battery is the fuel tank of the forklift. Look after it and it will look after you.”
Proper Battery Care
This video shares some tips on how to get the most life out of your battery and the do’s and don’ts when handling your battery and charger.
Battery maintenance is an extremely forgotten yet important factor; as knowing a little about forklift maintenance will go a long way. Proper battery care and watering can help extend the life of your industrial battery.
Everyday large, heavy and expensive batteries power electric forklifts and inevitably need to be re-charged. Waiting too long or making the wrong connection can cost your organization time and money.
Let Wayco keep track of your maintenance so it is done on time. To get the most out of your investment, machine operators should know and practice the proper care and maintenance of forklift batteries. Here are seven simple tips for proper battery maintenance:
Keep the battery dry, clean, and free from corrosion
Check that the battery charger cables are not damaged or showing heat damage.
Keep flames and metal away from battery top
Keep vent caps tightly in place
Maintain proper water level (about one half inch below the battery cap opening)
Add water only after the charge cycle. Add approved water only— never add acid
Set up a watering schedule either weekly or bi-monthly to ensure proper water levels
Avoid charging during break times and lunch breaks because each time you connect the battery to a charger, it uses one of its life cycles
Inspect for any defects or malfunctions, and have your battery service provider repair them as needed
Wash and service your battery semi-annually to help control acid and corrosion
Remember check fluid level approximately every five charge cycles, be sure to check the forklift battery fluid levels by opening up the battery.
Charging and Recharging
An electric forklift is designed to operate for one shift and then be charged on the next shift, overnight or if it is discharged more than 30%. It is up to the user to ensure that proper charging occurs so the battery performs as it was designed to.
Charging an electric forklift battery is not complicated; it just requires safety precautions and a consistent, orderly process. Properly charging a battery is all about doing it at the right time and for the right amount of time. Use these tips when charging your forklift battery:
Have a specific designated area for battery charging. Always charge a battery in a well ventilated area
Keeping a battery water log will help support a warranty claim.
Battery should be at 80% depth of discharge before charging; charging prior to the 80% can reduce battery life
If the battery overflows, rinse overflow will help prevent corrosion
Ensure the charger matches the voltage and amperage of the battery.
Avoid overcharging the battery which can reduce the battery life
Charge in proper temperature, extreme cold and heat can reduce service life
After charging cycle add water if needed. Use distilled or pure water to bring the electrolytes to the proper level. Equalize batteries regularly.
Never interrupt a charge cycle if it is unnecessary. It is suggested that once a charge has started, it should be allowed to finish.
Ensure the charger is turned off before connecting or disconnecting the battery.
Remember, a discharged battery that sits for extended periods will promote hard sulfation and reduce run time and life of the battery.
FAQ – People Also Ask…
What does it mean to equalize a battery?
An equalizing charge is nothing more than a deliberate overcharge to remove sulfate crystals that build up on the plates over time. Left unchecked, sulfation can reduce the overall capacity of the battery and render the battery unserviceable in extreme cases.
What does equalizing a battery do?
Equalizing is an overcharge performed on flooded lead acid batteries after they have been fully charged. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top.
Do you charge a battery after adding water?
The best time to water your batteries is always at the end of the charge cycle. However, if the electrolyte level is extremely low or the plates are exposed to air, add some water to cover the plates before starting the charge cycle
Can you put tap water in a battery?
Add distilled water to any cells in which the level of electrolyte isn’t touching the bottom of the fill port. Use only distilled water. The minerals in tap water will eventually reduce a battery’s capacity. If your battery is one of the so-called low-maintenance varieties, you may not see any filler caps
Why does the battery need to be recharged in a well ventilated area?
Because batteries release oxygen and hydrogen gases when they are charging, theareas should be well–ventilated with a fume hood or an exhaust fan to prevent explosions due to build-up of those gases. Using the proper tools and procedures, personnel can ensure the battery is stable during movement and doesn’t fall.
How many volts are in a forklift battery?
The forklift battery may require ten times more current output (measured in amperes) than the golf cart battery charger can provide. Voltages of 12, 24, 36, and 48 volts became convenient standards as industrial electric vehicles evolved
In order to extend their lifespan, forklift batteries must receive the right care, at the right time. If you follow a few simple steps, you can get the most from your batteries for years to come and prevent your battery from not holding a charge.
There are three most important things to insure your battery life!
Keep the battery charged
Keep the battery watered
Keep the battery cool
Put these simple measures in place to keep your battery healthy for longer. We hope you have grasped the benefits and basics of forklift battery maintenance. If you have any other questions on Wayco’s BATTERY Care program, please feel free to Ask Us anything related to forklift battery maintenance.
If you are in the market for a new forklift battery or any other forklift part, we can help. We also offer short-term and long-term forklift rentals.
Forklift Pre Shift Inspection Checklist: What to Do
How necessary is a forklift pre shift inspection? You do not want to cut corners, when you put your life in the hands of professionals. Pilots for example have a checklist for a pre-flight inspection before every flight and 99 times out of hundred everything checks out okay.
How necessary is a forklift pre-shift inspection? You do not want to cut corners when you put your life in the hands of professionals. Pilots, for example, have a checklist for a pre-flight inspection before every flight and 99 times out of a hundred everything checks out okay. But it’s the pre-flight inspection that contributes greatly to safe air travel. Just like a pilot, it is the responsibility of the operator of a lift truck to inspect the truck before the beginning of each shift and to keep a written record of the inspection. Read below for our checklist, or contact the experts at ForkliftHub Multi-Lift today!
Why Is A Forklift Pre Shift Inspection So Important?
Whether you own, lease, rent or borrow a forklift, the purpose of a pre-inspection is to look for damage and make sure the forklift is in good operating condition and meets the manufacturer's specifications.
It was cool when the Dukes of Hazard jumped into the General Lee and started the engine. But you don’t want your certified forklift operators to engage in such practices. Instead, you want them to conduct an inspection before taking their seat and starting the equipment. Safety begins with knowing as much as possible.
Forklifts are used in thousands of workplaces, but they continue to be a significant cause of serious worker injury and death. The Occupational Health and Safety Act, known as OHSA, says one in 15 forklift accidents is caused by improper maintenance.
A pre-shift inspection can identify maintenance problems before they cause an accident. Safety begins with knowing as much as possible about each forklift model so it’s extremely important to read and fully understand the operator manual before operating the forklift
Forklift Pre Shift Inspection Checklist
Part 1: Beginning The Inspection
Wayco’s Forklift Operators Checklist booklet provides outlined items to be inspected daily. At the beginning of a shift take a few minutes to carefully inspect the forklift.
No matter how often you use the lift equipment an inspection must be done every day prior to use. The operator should have an actual physical list of each inspection item, checking them off as they move down the list from top to bottom.
No matter how experienced the operator is, you can not rely on a mental list. Every pre-start check should consist of a visual pre-check and an operational pre-check.
Part 2: What Specifically Should Operators Check?
A forklift pre-shift inspection starts with a walk around the forklift. The next step is to make a number of visual checks.
Forks must be level so look for excessive wear or cracks in the hanger welding or in the heel. The forks must be evenly spaced and the four pins locked into place.
Check all the tires for damage and excessive wear such as cracks. Remove any debris from around the wheels
Mast assembly check for any leaks or drips; ensure the hydraulic hoses do not have any punctures or cuts. Check it is free of foreign objects such as pieces of wood or wire.
Make sure the tension of the chain is nice and tight; also make sure it is well-lubricated.
Ensure that the load backrest is not damaged and is securely fastened.
Check the seat belt is in good working order.
See if all safety equipment is attached and in good working order such as fire extinguishers, mirrors, safety labels and capacity plates.
Check the propane tank to make sure it is secure. Smell and listen to the connections for any leaks. Frosting will indicate a leak. If electric, make sure the battery cables are clean and connected.
Look at the radiator to make sure it is clear of debris or trash.
Part 3: Three-Point Entry And Exit
Now we are going to talk about the three-point entry and exit shown in the video below. Three-point entry refers to how we properly get on and off the forklift at all times. Three points of your body are in contact with the machine at all times.
Enter and exit with two hands and a foot onto the truck to sit down or of course to get off the forklift. If you have any questions about the contact points on your particular tuck, you can always check with your manufacturer or with the operator’s manual of the truck. Always put your seat belt on.
The video below will show you extra facts about forklifts and more safety tips including:
Operator Safety Training
Before You Start Your Shift
Lifting and Placing Loads
Refuelling / Recharging
Other types of Powered Industrial Trucks
Maintenance & Modifications
Part 4: Forklift Pre-Shift Inspection Continued
The final steps in a pre-inspection check are as follows:
Put your foot on the brake, turn on the forklift, put it in forward, and take the brake off. If the forklift does not move, then the emergency brake is working.
Test all brakes, including the foot brake, the parking brake, and the deadman seat brake that stops the vehicle when the operator stands up.
Listen for unusual noises.
Check that the controls are clearly marked and that the seat and steering wheel are secure and properly adjusted.
Check that the horn, alarm, gauges, and lights are all working,
Check that the engine oil light is not on.
Put your foot back on the brake, put it in neutral and turn off the forklift.
If any items are found to be unsafe or need repair, the forklift needs to be taken out of service and red-tagged until repaired. Report any problems in the daily check to the supervisor immediately.
Make this forklift pre-shift inspection checklist available to all forklift and lift equipment operators; and be sure they provide space to enter detailed comments about any findings, damage or concerns.
Inspecting your forklift as required by OHSA is not only a good idea to maintain compliance, but it is a best practice for any forklift fleet. At ForkliftHub, we found it pays for itself over time with reduced maintenance costs, accidents and product/ facility damage.
Looking For a Forklift Pre Inspection Form?
Forklift pre-inspection forms will make your pre-inspection process easier and more efficient for your workers.
For a complete checklist form, you can place your order right here. Using the forklift pre-inspection form will guide operators through all the important steps.
A key component to a successful business is keeping your workplace safe and ensuring that your equipment is up-to-date and fit for your employees to operate.
We have other safety products available such as lock-out tags, Battery PPE kits and more! Contact Forklift Hub today if you have any further forklift or safety-related questions. We’d be glad to help in any way we can.
Top 5 Forklift Accident Videos (+Safety Infographic!)
What factors contribute to a forklift accident? Poor training, carelessness, unbalanced or unsecured loads, ignoring safety guidelines to name a few: Find out the rest.
A forklift accident can cause serious bodily harm or even death; learn from these mistakes and get proper training so this never happens to you! What factors contribute to a forklift accident? Take a look at these top 5 forklift accident videos and you will find out. There are countless horror stories about forklifts in the workplace. We’re going to check some of them in this post, explain what went wrong, and how proper safety policies and training could have prevented them. Train your employees and don’t let this happen to them.
Looking for hands-on, practical
safety training?
#1 - Ten Videos of Forklift Accidents that show Why Training is Important
Summary: This great 5 minute video counts down ten different forklift accidents that could have been prevented with proper training. You may think this would never happen, but it does, as the video evidence proves. You will witness how quickly things can go wrong from forklift stunts, crashes, bottle breaking and collapsed shelves.
The Main Takeaway: The cost of proper training is minimal in comparison to what the costs could be in lost product and damaged equipment.
Video Maker: The Top 10 of Anything and Everything
#2 - Warehouse Fails
Summary: Accidents like the ones in the next video happen, but nobody thinks it’s serious until some guy has his fingers crushed or his foot run over and his heel crushed. Here we have a series of warehouse video footage that shows examples of poor driving skills as well as the improper use of forklift equipment. Some of the videos demonstrate extensive damage to product and others show individuals getting seriously injured.
The Main Takeaway: Some forklift accidents are a result of carelessness, but there is never a time when horseplay is appropriate. Some of these shenanigans at these warehouses look harmless, but they could hurt or kill someone. The dangers of workplace horseplay like speeding or stunt driving with a forklift can cause possibly injury to the driver or innocent pedestrians. Most accidents are caused by unsafe acts—and horseplay itself is an unsafe act.
Video Maker: YokoHammer91
#3 - Forklift Fails - Forklift Accidents Caught on Camera
Summary: There you have It! This video shows us that loading and unloading can be costly. We see examples of having too of heavy loads, using the wrong equipment, and a forklift falling off the edge of the pavement. Some of these warehouse forklift accidents are a recipe for eventual disaster. The scariest one is of an older man falling when unloading the truck. He launches 3 meters up in the air and does a face plant. A loading dock is a dangerous place for forklift operators
The Main Takeaway: Forklifts weigh several thousand pounds making it a dangerous vehicle. Those racks falling are no joke. It takes one little break in concentration to have an accident. It is critical that loads are secured and carefully centered on the forks to ensure the weight is distributed properly so that balance is maintained when loading and unloading.
Video Maker: TNT Channel
#4 - Don’t Do This!
Summary: How can these forklift accidents happen? These top ten videos collections cover embarrassing mishaps from loading and offloading, colleagues who are determined to get the product unloaded even if it means toppling over, a driver who is unaware of a pedestrian, and everything in between. Lack of safety precautions could cost your business – and worst of all – your life.
The Main Takeaway: Here are a few tips to prevent some of these accidents: you should make sure your load is secure, use proper equipment, look out for pedestrians, and take special care on loading docks. We could list more but our advice is, if it looks dangerous, then it probably is. Simple, safe practices, such as wearing correctly fitted seat belts, observing speed limits and warning signs; slowing down; and sounding the horn at an intersection can make a big difference.
Video Maker: ForkliftBriefing
#5 - Forklift Accident Brings Down The Warehouse
Summary: The forklift accident in this next video looks just like an earthquake shook this warehouse. Luckily no one was seriously injured. One small forklift accident moment can cost tons of money and days of work cleaning it up. The driver in the video hits the first shelf just hard enough to start a domino effect bringing down all the shelving in the entire warehouse.
The Main Takeaway: Was it the driver’s fault or were the shelves poorly constructed? We are not sure, but it is safe to say that all aspects of a warehouse safety should be checked from racking, to maintaining clear paths in aisles, not just enforcing forklift operator training.
Video Maker: JustaTest2010
Forklift Hazards - An Infographic
Learn about the most common forklift hazards so you can avoid these common mistakes!
Stay Safe On The Job - Train With Forklift Hub Today!
Here at Forklift Hub, we provide safety programs that help train your employees to operate safely in the workplace. Forklift accidents are preventable with proper training. It is also important that everyone who works around powered industrial trucks become familiar with the safety rules.
You probably feel relatively safe walking around forklifts, right? Most people do. However, companies need to create safer warehouses for pedestrians & forklifts to prevent forklift accidents. Contact us today to find out more about how one of our safety training programs could help ensure that incidents like these never happen in your workplace.
