DISCLAIMER: This document discusses forklifts.
Forklifts are a type of Powered Industrial Truck (PIT) and
must meet the applicable standard requirements found
in Chapter 296-863 WAC. Forklifts are not the ONLY type
of PIT. Each piece of equipment must be evaluated to
determine whether or not it meets the definition and is
covered by the standard.
Contents
How This Book Can Help Prevent
Forklift Accidents............................1
Introduction .................................2
Types of Forklifts ............................3
Forklift Operators Must be Trained ............6
How a Forklift Works ........................8
Safely Using a Forklift.......................15
Driving Indoors and In Other
Enclosed Locations .........................23
Driving Indoors and In Other
Enclosed Locations .........................24
Maintenance of Forklifts ....................27
Summary...................................28
Resources .................................30
Get 1-on-1 Assistance .......................31
1
How This Book Can Help Prevent Forklift Accidents
This book has general information about:
The kinds of forklifts and powered
industrial trucks commonly available.
The principles that allow a forklift to lift
and move heavy loads safely.
Forklift operator training requirements.
Basic operator safety rules.
Hazardous locations where carbon
monoxide is a problem or a special
forklift is needed.
Safety while servicing a forklift.
This book is not designed to substitute for
operator training in the operation of specic
forklifts and other powered industrial trucks
used in your workplace.
Whenever you see this symbol in the
book, it means that failure to follow the
instructions can result in serious injury
or death.
L&I’s Standards That Regulate Forklifts
Safety rules developed under the Washington
Industrial Safety and Health Act (WISHA)
regulate the safe use of powered industrial
trucks in Washington workplaces. You can
nd these rules in:
WAC 296-863:
Forklifts and other Powered
Industrial Trucks
WAC 296-155:
Construction Standard
WAC 296-307-520:
Agriculture Standard
WAC 296-56-60077:
Longshore, Stevedore and Related
Waterfront Standard
You can get a copy of these rules on our
website at www.Lni.wa.gov/Safety or by
calling the L&I ofce nearest you.
2
Introduction
A forklift is a powerful tool that allows one
person to precisely lift, move and place large
heavy loads with little effort. Using a tool
such as a forklift, cart or hand truck instead of
lifting and carrying items by hand can reduce
the risk of suffering a back injury.
However, there is great risk of injury or death
when a forklift operator:
Has not been trained in the principles
of physics that allows a forklift to lift
heavy loads.
Is not familiar with how a particular
forklift operates.
Operates the forklift carelessly, unsafely
or without knowing the hazards
Uses a forklift that is not safe due
to malfunctioning, missing parts or
unapproved alterations.
Approximately 35,000 serious injuries and
62,000 non-serious injuries involving forklifts
occur in the United States every year. OSHA
estimates 11% of all forklifts are involved in
accidents every year.
Fatal accident type Percentage
Crushed by vehicle tipping over 42%
Crushed between vehicle and
a surface
25%
Crushed between two vehicles 11%
Struck or run over by a forklift 10%
Struck by falling material 8%
Fall from platform on the forks 4%
A forklift operator was pinned and killed when the forklift
the worker was operating overturned.
3
Types of Forklifts
A forklift is a type of powered industrial
truck (PIT) covered by safety standards. A
PIT is a mobile, power-driven vehicle used to
carry, push, pull, lift, stack or tier material.
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 re or explosion.
There are several different types of PITs that
are used in different types of industries. Some
of the types are shown below.
Electric Motor Counter-Balanced Trucks
(solid and pneumatic tires)
Sit-Down Rider
The forklift has a counter balance weight in the body.
Electric Motor Narrow Aisle Trucks
(solid tires)
Stand-Up Rider Narrow Aisle
The forklift has straddle legs on both sides of the forks
to provide stability in the absence of a counterweight in
the body.
Electric Motor Hand Trucks or Hand/Rider
Trucks (solid tires)
Motorized Hand Pallet Jack
A low-lift (ground level) unit has forks or a platform.
Some models allow the operator to stand on the back.
Others are walked. A high-lift version has a mast and
straddle legs.
4
Types of Forklifts
Internal Combustion Engine Trucks
(solid tires)
Sit-Down Rider
The forklift has a counter balance in the rear.
Electric and Internal Combustion Engine
Tractors (solid and pneumatic tires)
Sit-Down Rider
The forklift has a draw bar that is capable of pulling
heavy loads.
Internal Combustion Engine Trucks
(pneumatic tires)
Sit-Down Rider
The forklift has a counter balance in the rear.
Rough Terrain Forklift Trucks
(pneumatic tires)
Rough-Terrain Reach Forklift
The forklift has large pneumatic tires, and a boom which
raises and extends. Outriggers at the front stabilize the
forklift on soft or uneven ground.
A rough-terrain forklift might also resemble a sit-down
rider as shown above. However, it is bigger with large
pneumatic tires and a large mast with large forks. It is
powered by an internal combustion engine.
5
Types of Forklifts
Sometimes special attachments are installed
onto the forks to extend the reach, clamp a
barrel, act as hoist, lift odd-shaped items like a
roll of carpet or even lift people.
Using an unapproved attachment could
alter the forklift’s lifting and balance
characteristics and cause the forklift
to overturn.
Whenever an attachment is used that could
affect the capacity or safe operation of a
forklift, its use must be approved by the
forklift manufacturer. The employer must
mark the forklift to show the new weight with
attachment. The maximum capacity at the
highest elevation must also be shown.
Hoist Attachment Personnel Platform
Jib Crane Attachment
Drum Grabber Attachment
Carpet Lifting Attachment
6
Forklift Operators Must be Trained
An untrained forklift operator can be as
dangerous as an unlicensed driver of a
motor vehicle.
State regulations require the employer
to ensure that a forklift operator is
competent to operate the forklift he or
she is assigned to use. The employer
must document operator training and an
evaluation of the operator’s performance
while using the forklift.
The topics listed below must be covered when
training a forklift operator. However, if a
specic topic does not apply to the forklift in the
employer’s workplace, covering it is optional.
Forklift operators must be trained in the operating
instructions, warnings and precautions for the types of
forklifts they will be authorized to use.
Topics related to forklifts
Operating instructions
Warnings and precautions for the types
of forklift the operator will be authorized
to operate
Differences between a forklift and
automobile
Controls and instrumentation: Where
they are located, what they do and how
they work
Engine or motor operation
Steering and maneuvering
Visibility (including restrictions due
to loading)
Fork and attachment adaptation,
operation and use limitations
Forklift capacity
Forklift stability
Any inspection and maintenance that the
operator will be required to perform
Refueling
Charging and recharging of batteries
Operating limitations
Any other operating instructions, warnings
or precautions listed in the operator’s
manual for the types of forklift that the
employee is being trained to operate
Topics related to your workplace
Surface conditions where the forklift will
be operated
Composition of loads to be carried and
load stability
Load manipulation, stacking
and un-stacking
7
Forklift Operators Must be Trained
Pedestrian trafc in areas where the
forklift will be operated
Narrow aisles and other restricted places
where the forklift will be operated
Use of door opening and closing devices
Hazardous (classied) locations where
the forklift will be operated
Ramps and other sloped surfaces that
could affect the forklift’s stability
Closed environments and other areas
where insufcient ventilation or poor
maintenance could cause a buildup of
carbon monoxide or diesel exhaust
Other unique or potentially hazardous
environmental conditions in the
workplace that could affect safe operation
Qualied Trainers: The employer or any
other person the employer chooses who has
the knowledge, training and experience to
train and evaluate forklift operators can do
this training and evaluation. The trainee
can operate the forklift only when directly
supervised by such a person and when this
would not endanger anyone.
Documenting Training: If the operator
had previous forklift training, the employer
must document that the training covered the
required topics described above. The operator
must have been evaluated in the current
workplace within the last three years.
Training and Evaluation Records: The
employer must keep a record that shows that
each forklift operator has been trained. The
record must include the name of the operator,
date of training, date of evaluation and the
name of the person(s) giving the training
and evaluation.
Refresher training must be given if the
operator has been involved in an accident, a
near miss or unsafe operations. Also, if an
operator is assigned to a new type of forklift
or if workplace conditions change and an
evaluation shows they are not operating it
safely, then refresher training is required.
8
How a Forklift Works
Driving a Forklift is Different Than
Driving a Car
In a car or truck, the front wheels steer the
vehicle. A forklift has the steering wheels in
the rear. The rear end of the forklift swings in
a circle around the front wheels that support
most of the load. The operator must check
that there is room for the rear end to swing
when making turns. This clearance can be
maintained in your workplace by permanently
marking aisles with painted lines or arranging
storage racks in a way that creates obvious
aisles for travel. However, these marked aisles
will only be effective if you keep them clear of
stored materials, which can gradually encroach
as space is needed.
A forklift is not as responsive when turning
the steering wheel. Rear steering makes it
difcult to stop a forklift quickly or swerve and
still maintain control. It is important then not
to drive a forklift fast or round corners quickly.
Driving with the load downhill can
result in loss of the load and control of
the forklift.
If you drive a forklift on an incline, you must
keep the load on the uphill side. Otherwise,
you may have no weight on the wheels that
steer and can lose control! The load could also
fall off or cause the forklift to tip.
Often a large load obstructs the driver’s view
in one direction. It may be necessary to travel
long distances with the load to the rear (in
reverse for most forklifts). Use extra caution
when traveling in reverse.
Mark aisles to help keep adequate clearance for forklifts.
Keep the load uphill to maintain control of the forklift.
9
How a Forklift Works
Forklift Safety Features
A backrest extension on the forks prevents part
of the load from falling rearward toward the
operator. This is required when loads are lifted
high and the type of load would allow all or
part of it to fall to the rear under conditions
such as acceleration, sudden stops or driving
on an uneven surface.
An overhead guard prevents an object on
the forks or on a high rack from falling onto
the operator while picking or placing a load
at elevation. The guard is not designed to
withstand the impact from a full load. It can
be effective in deecting small packages. It
is required on all forklifts that can lift a load
above the operator unless conditions such
as clearances would not allow the forklift to
be used.
Operator restraints will hold you in the
seat if you strike an object or if the forklift
overturns. Many forklift manufacturers offer
restraint systems that can be retrotted on
older forklifts.
If your forklift begins to overturn, you are
safest when you stay in the seat, hold on
rmly, and lean in the opposite direction of
the fall rather than trying to jump. Many fatal
accidents happened when the operator tried to
jump. As the forklift begins to tip, it will move
slowly
—
tricking the operator into believing
there is time to jump. Once the center of
gravity is past the wheel line, the forklift will
rapidly fall. The forklift’s overhead guard will
quickly pin or crush an operator who jumps.
A backrest extension keeps the load
from falling rearward.
An overhead guard can deflect objects falling
from above.
10
How a Forklift Works
Failure to wear a seat belt can result in
the operator being thrown outside the
protective cage in the event of an overturn.
If your forklift has a restraint such as a seat
belt or a lap bar, you must use it.
How Forklifts Safely Carry and Lift
Heavy Loads
A forklift works on the principle of a
cantilever. A load on a beam (the forks)
supported by a fulcrum (the front wheels)
is counterbalanced by a weight on the other
end of the beam (the forklift body and
counterweight built into it).
Whether a forklift will safely carry a load
or will tip forward can be determined by
comparing the “moment” of each.
Moment equals the distance from the fulcrum
to the center of gravity (the point where all the
weight is concentrated) times the weight.
Wear a seat belt to keep you inside if your forklift overturns.
Example: An evenly distributed 36-inch-wide
load on the forks has a center of gravity that
is 18 inches from the face of the forks.
1
If
the load weighs 4,000 pounds, then the load
moment will be 72,000 inch-pounds (18 inches
x 4,000 pounds).
If the “moment” of the forklift is greater than
or equal to the 72,000 inch-pounds of the load,
then the forklift will safely carry the load.
Forklifts have a capacity plate to tell the user
what loads are safe to lift. If the plate says
the capacity is 30,000 pounds or less, then
that capacity is rated for a load with a center
of gravity 24 inches from the face of the
forks. If the forklift capacity is greater than
30,000 pounds, then the label will rate the
load at a 36-inch or 48-inch center of gravity,
since larger forklifts usually lift physically
larger loads.
1. The fulcrum point is actually at the center of the wheel. Forklift
load charts, however, are adjusted to allow measuring from the
face of the forks.
11
How a Forklift Works
Capacity Forklift Type Attachment ID
Capacity with Attachment
This LP Gas Forklift can safely lift 5,000 pounds 173 inches
high with a center of gravity 24 inches from the face of
the forks. With an attachment labeled “HSS,” the safe
load drops to 4,500 pounds.
As the load is raised, it becomes possible for
the forklift to fall to the side as well as tip
forward. The operator must consider the center
of gravity of the forklift and load together. This
combined center of gravity moves as the load is
moved and as the forklift travels over surfaces
that are rough or inclined.
Forklift Moment: 24” x 5,000 lbs. = 120,000 inch-pounds
Load Moment: 18” x 4,000 lbs. = 72,000 inch-pounds
The load is safe to lift because load moment is less than
forklift moment.
However, if the 4,000-pound load was 66 inches wide,
the load moment would be 132,000 inch-pounds
(33” x 4,000 lbs.), which would be greater than the
moment of the forklift. The forklift would tip forward.
12
How a Forklift Works
Forklifts have a “stability triangle.” The sides of the triangle as shown in the
illustration are formed by the center of each front wheel and the center of
the rear wheel, or at the center of the axle if there are two rear wheels.
A vertical line extending from the center of gravity
of the vehicle-load combination must be inside of the
stability triangle to prevent the forklift from tipping
forward, falling sideways or dropping its load.
The center of gravity of the forklift-load
combination can move outside the stability
triangle if:
The load is picked up on the tip of the forks
The load is tilted forward
The load is tilted too far back
when raised
The load is wide
Forklift movement causes the
center of gravity to shift.
Stability
Triangle and
Center of
Gravity
Unloaded Forklift
Maximum
Load with mast
vertical
Forklift + load
center of gravity
Unstable
Stable
Unloaded forklift’s
center of gravity
These actions will have the following effects:
Action Center of gravity moves
Tilting the load forward
Toward the front axle
Raising the load while tilted forward
Driving on an incline with the load downhill
Stopping forward travel or accelerating backward
Tilting the load back
Toward the rear axle
Raising the load while tilted back
Driving on an incline with the load uphill
Accelerating forward or stopping backward travel
Driving across an inclined surface Toward the downhill side of the triangle
Driving across a rough or uneven surface Toward the rut or low side of the triangle
Turning Toward the side now facing the original direction of travel
13
How a Forklift Works
This list represents operator procedures
that reduce the risk of overturn, collision
or loss of the load.
To prevent your forklift from tipping over,
falling sideways or dropping its load:
Make sure the load is stable and safely
secured on the forks.
Do not tilt the forks forward except when
picking up or depositing a load.
Tilt the load backward only enough to
stabilize the load.
Keep the load low when traveling.
Cross railroad tracks diagonally
when possible.
Enter elevators squarely.
Keep the load uphill when going up or
down an incline.
Drive at a speed that will allow you to
stop safely within the stability triangle.
Slow down on wet or slippery surfaces.
Slow down to make turns, and honk if
there is trafc.
Avoid driving over loose objects or on
surfaces with ruts and holes.
Do not allow unauthorized people to ride
on forklifts.
Do not allow stunt driving or horseplay.
Failure to check that the forklift is
operating properly can lead to an accident,
as the description below demonstrates.
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 five
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.
14
How a Forklift Works
Pre-use Inspection Checklist
The forklift must be checked for defects
daily
—
usually by the operator or a
designated person prior to beginning and
after 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 re?
■
Do sparks or ames 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.
■
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.
Appendix A is a sample operator pre-use
inspection checklist.
15
Safely Using a Forklift
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.
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.
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 xed 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.
16
Safely Using a Forklift
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, blocked or
secured, it can suddenly move over time or
with the right amount of force. The dock
board can also fall between the trailer and the
dock as the forklift crosses it.
You can secure wheel chocks with a 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.
Trucks or trailers must be chocked or blocked at the
wheels, or with a mechanical device that secures the
truck or trailer to the loading dock. Notice the sign tells
drivers to chock the wheels.
Dock mounted vehicle
restraint clamps to a
bar under the truck.
Trailer jack.
17
Safely Using a Forklift
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 ngers
and make for safe handling, a portable dock
board must also have handholds, lugs or an
equally effective means that allow the forklift
to pick it up.
Keep a safe distance from the edge of a
loading dock or a ramp. To help operators
keep a safe distance, the edge of a dock could
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. In a maritime
setting, bull rails help prevent wheels from
slipping off the sides of ramps or edges of the
dock where a forklift would not have to cross
to enter a trailer.
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.
18
Safely Using a Forklift
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.
Block Brick Pinwheel Irregular Stacking Patterns
The most common.
The upper level may be
unstable if not encircled
with wire or strapping.
Containers are
interlocked by
turning each level
90 degrees.
Used where brick
pattern is unstable.
Wood strips, plywood or heavy cardboard
between layers can help stabilize castings,
bags and other irregular shapes.
Check the destination before you place
the load:
Is the destination at 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.
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.
19
Safely Using a Forklift
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?
Are racks secured to the oor or other
adjacent structures?
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 or lowering a person on forks or a
pallet can result in a fall injury or ngers
caught in moving parts of the mast.
Check that wood stringers or decking in racks are in good
condition. They may not support the load if the pallet is
not properly placed on both front and rear rails.
Never stand
on the forks or
a pallet to
work at an
elevated level.
20
Safely Using a Forklift
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 specically built for this
purpose that meets these conditions:
The platform must be approved by the
manufacturer and have standard guardrails
which include a top rail 39 to 45 inches above
the midrail and toeboard. It must also prevent
contact with chains and shear points on the
mast. See the illustration below for an example.
The platform must be securely attached
to the forks, such as by a clamp or chain.
Must have nameplate and label attached
to the forklift.
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 within 25 feet of the forklift while a
worker is elevated.
Do not move the forklift between two
points when a worker is on the platform.
Fall from Forklift
A 47-year-old male assistant warehouse
manager was fatally injured while
working with a forklift operator to pull
tires from a storage rack. The two
workers placed a wooden pallet on the
forks of the forklift and the victim then
stood on the pallet. The operator raised
the forks and victim 16 feet above a
concrete floor. The victim had placed a
few tires on the pallet when the operator
noticed that the pallet was becoming
unstable. The victim lost his balance and
fell, striking his head on the floor.
Forklift work platform
has standard
guardrails and a
screen to prevent
contact with moving
parts of the mast. A
chain secures the
platform to the mast.
21
Safely Using a Forklift
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.
The following practices are designed to
prevent explosion of ammable vapors due to
spark or collision with unprotected fuel tanks.
Fueling/Charging
When refueling or charging batteries, observe the
following precautions:
Do not smoke or allow any open ames
or spark/arc generating equipment in the
refueling/charging area.
Make sure there is adequate ventilation to
disburse fumes.
Make sure there is a re 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.
The operator of an
order-picker-type
forklift must wear a
safety harness to
protect against the
fall hazard at an
elevated location.
Propane tank used to refill the forklift LPG tank is
protected against vehicle damage by heavy posts
and must be well ventilated and not near any
ignition sources.
22
Safely Using a Forklift
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 uid 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 ush 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.
An eyewash or eyewash
with shower must be
available when doing
battery service beyond
routine charging.
23
Driving Indoors and In Other Enclosed Locations
Carbon Monoxide Hazard
Internal combustion engines produce
carbon monoxide. This gas can rapidly
build up in any indoor area. People can
be overcome without even realizing they
are being exposed. Confusion, headache,
dizziness, fatigue and weakness may set in
too quickly for victims to save themselves.
Carbon monoxide poisoning can cause
permanent brain damage, including changes
in personality and memory. Once inhaled,
carbon monoxide decreases the ability of
the blood to carry oxygen to the brain and
other vital organs. Even low levels of carbon
monoxide can set off chest pains and heart
attacks in people with coronary artery disease.
State standards (WAC 296-841) set the
maximum allowable exposure to carbon
monoxide. Gasoline or diesel-powered
forklifts should not be used indoors unless
space is well ventilated. Propane forklifts
also produce carbon monoxide and must be
regularly inspected and maintained. If you
are concerned about the exposure level in
an enclosed area where a forklift operates,
contact a qualied industrial hygienist to
make measurements and recommendations to
improve ventilation.
Operating a forklift in an environment where
chemicals or other substances are present
can be hazardous. Use only forklifts that are
designed for operations under those conditions!
To select the appropriate forklift, you must
know the type of location (Class), the name
of the chemical or substance and how likely
it is that the hazardous condition would be
present (Division).
Internal combustion engine forklifts can cause carbon
monoxide poisoning when used indoors if the engine is
not kept tuned and the area well ventilated.
Terms
Class I locations are areas that contain
ammable gases or vapors or where they
may be present in the air in quantities
sufcient to produce explosive or
ignitable mixtures.
Class II locations are areas where the
presence of combustible dust could be
sufcient to produce explosions.
Class III locations are areas where the
presence of easily ignitable bers are
suspended in the air but are not in
large enough quantities to produce
ignitable mixtures.
An unclassied location is an area that is
not designated as a Class I, II or III location.
24
Driving Indoors and In Other Enclosed Locations
Use the table below to select a
safe forklift.
Look in the rst column
of the table for the hazard
class of the material.
Find the row that has the
chemical or substance
handled.
Choose the second or
third column based on the
division that represents the
exposure condition.
To interpret the hazard
designations listed in the
second or third column,
refer to the table at right.
Explosion/Combustion Hazards
All forklifts have a hazard designation assigned to them that tells
whether they are suitable for use in certain kinds of hazardous
atmospheres. You can nd the designation on the forklift’s load
capacity plate. The table below explains the designations.
Hazard Designation Descriptions
Type Built-in Safeguards Against Fire Hazards
D (Diesel
forklift)
Minimum
DS
D + additional for fuel, exhaust and
electrical systems
DY DS + all electrical equipment enclosed
E Minimum
ES
E + prevents sparks and limits surface
temperatures
EE
ES + all electric motors and equipment
completely enclosed
EX
Can be used in flammable vapor or dust
atmospheres
G (Gasoline
forklift)
Minimum
GS
G + additional for fuel, exhaust and
electrical systems
LP G + minimum safeguards for liquid petroleum gas
LPS
LP + additional for fuel, exhaust and
electrical systems
25
If you work in an area where this
hazard classification is present:
Then use this type of forklift.
(See hazard designation descriptions above.)
Class I
Flammable gases or vapors are or may
be present in quantities sufficient for
explosion or ignition.
Division I
Condition exists continuously,
intermittently, or periodically under
normal operating conditions.
Division II
Condition may occur
accidentally e.g., puncture
of a storage drum.
Acetylene, acetaldehyde, butadiene,
cyclopropane, diethyl ether, ethylene,
ethylene oxide, isoprene, propylene
oxide, hydrogen (or gases or vapors
equivalent in hazard to hydrogen, such
as manufactured gas), unsymmetrical
dimenthyl hydrazine (UDMH).
Forklift use prohibited. DY, EE, EX (also DS, ES, GS,
LPS) if the only exposure is
sealed containers or liquefied
or compressed gases in
containers.
Acetone, acrylonitrile, alcohol, ammonia,
benzine, bensol, butane, ethylene
dichloride, gasoline, hexane, lacquer
solvent, natural gas, naphtha, propane,
propylene, styrene, xylenes, vinyl
acetate, vinyl chloride.
EX DY, EE, EX (also DS, ES, GS,
LPS) if the only exposure is
sealed containers or liquefied
or compressed gases in
containers.
Class II
Combustible dust is present.
Division I
Explosive or conductive mixture
may be present under normal
conditions or where equipment
failure can lead to both this
condition and arching or sparking.
Division II
Explosive mixture not
normally present but where
deposits of dust may cause
heat rise in electrical
equipment.
Aluminum, magnesium, and their
commercial alloys; other metals of
similarly hazardous characteristics.
Forklift use prohibited. Forklift with electrical
enclosures manufacturer
approved where magnesium,
aluminum or aluminum bronze
may be present.
Carbon black, coal or coke dust. EX Forklift manufacturer
approved for this location.
Other combustible dusts. EX DY, EE, EX
26
If you work in an area where this
hazard classification is present:
Then use this type of forklift.
(See hazard designation descriptions above.)
Class III
Easily ignitable fibers or flyings are
present but not likely to be in
suspension in quantities sufficient
to ignite.
Division I
Locations in which these
materials are handled,
manufactured or used.
Division II
Locations in which these
materials are stored
or handled (other than
manufacture).
Baled waste, cocoa fiber, cotton,
excelsior, hemp, istle, jute, kapok,
oakum, sisal, Spanish moss, synthetic
fibers, tow.
DY, EE, EX DS, DY, ES, EE, GS, LPS
(Type E may continue to be
used if used previously at this
location.)
Unclassified Locations
Piers and wharves inside and outside
general storage, general industrial or
commercial properties.
D, E, G, LP (more protective designations may also be used)
27
Maintenance of Forklifts
“Out of Service” and Required
Check Intervals
State regulations require that a forklift be
checked for defects the rst time it is placed
in service and every day that the forklift is
used. If the forklift is used continuously, then
it must be checked at the end of each shift.
Appendix A is a sample operator’s “Daily
Forklift Safety Checklist” that can be attached
to the forklift as a reminder to the operator to
do this check. Some employers keep records
of these daily checks.
If a forklift is found unsafe, then it must be
removed from service until repaired by an
authorized person.
In addition, the forklift owner’s manual
will have routine checks and preventive
maintenance tasks that must be done by
a skilled maintenance person to keep
the forklift in safe operating condition.
Keep a record of this maintenance as well
as any repairs that are made. A safety
compliance ofcer assigned to investigate an
accident involving a forklift will ask to see
maintenance and repair records. If you do not
have records, it will be impossible for you to
prove any maintenance was done and may
result in a citation.
When you replace parts, make sure they
are equivalent to the original manufactured
part. If the forklift was designed to operate
in a hazardous (classied) location, ensure
that any repairs meet UL or other testing
laboratory requirements.
Do not alter or eliminate any forklift parts
or add any accessories such as additional
counterweights or lifting attachments unless
approved by the manufacturer in writing.
Make any necessary changes to the load
capacity plate and operating instructions.
Safety in the Maintenance Area
To prevent injury or illness when doing
maintenance on a forklift:
Do not do repairs in an area with a
potentially ammable or combustible
atmosphere (Class I, II, or III as described
previously).
Make sure there is adequate ventilation
to prevent accumulation of exhaust or
gas fumes.
Do not use ammable solvent to clean
a forklift. Use a non-combustible (ash
point above 100º F) solvent.
Never get under a forklift supported only
by a jack or under any part supported
only by hydraulic pressure! Install jack
stands or a secure block support.
To prevent the forklift from accidentally
being started, remove and keep control
of the key or disconnect the battery while
making repairs. If the electrical system
will be serviced, you must disconnect the
battery before starting repairs.
28
Summary
A forklift is a powerful tool when used by
a well-trained operator. It allows workers to
move and organize heavy materials.
However, it can expose workers to serious
hazards which can result in injuries and in
some cases even death.
To prevent or eliminate worker exposure to
these hazards:
Use the appropriate forklift and
attachments based on the driving
location, size of load and potential for
hazardous atmosphere.
Make sure that forklift operators are
given formal instruction, hands-on
training and periodic evaluation as
required by state regulations.
Observe forklift operators in their daily
work and take prompt corrective action
to correct careless or unsafe operations.
Maintain forklifts in safe condition
free of defective or missing parts
through daily visual checks and regular
preventive maintenance.
To view or print a summary guide to
forklift safety, visit
www.Lni.wa.gov/go/F417-202-000
Division of Occupational Safety and Health
www.Lni.wa.gov/safety-health
1-800-423-7233
Forklift Safety
Training requirements and helpful tips
A forklift is a powerful tool that allows one person to
precisely lift and place large, heavy loads with little
effort. However, there is a great risk of injury or death
when a forklift operator has not been trained.
Must employees be trained?
Yes. All employees operating a forklift must be trained.
The training consists of three elements: formal (general,
classroom-type) training, practical (site-specic, hands-
on) training and a visual evaluation of the operator’s skill.
Does an employer have to hire a professional
trainer to give the training?
No. Anyone who has the knowledge, training and
experience to train and evaluate forklift operators can
conduct the training.
Can an employer develop their own training program?
Yes. An employer can develop their own program
using, for example, WISHA Codes, Forklift Safety
Guide, videos, an owner’s manual review, or a hands-on
training session. Additionally, the trainer would observe
the operator and evaluate their ability to safely operate
the forklift. Topics that must be covered during training
and evaluation are listed on the back of this fact sheet.
Does the employee have to be evaluated after
being trained?
Yes. After completing the classroom and hands-on
training, the employee must demonstrate the skills
learned. An evaluator designated by the employer must
visually evaluate these skills. Additionally, all employees
must be evaluated every three years to ensure that they
are still operating the forklifts in a safe manner.
Does training have to be documented?
Yes. The employer must keep a record of forklift training
and the evaluation. The record includes the name of the
operator, date of the training, date of evaluation and the
name of the person(s) giving the training and evaluation.
Does training from a previous employer count?
Yes and no. Training received from a previous
employer can meet the general, classroom-type training
requirement, if such training was appropriate to the
forklift and working conditions encountered and if
the operator was evaluated and found competent to
operate the forklift safely within three years. However,
the current employer is still responsible for site-
specic hands-on training for the specic forklift that
the employee will be using. Additionally, the current
employer is required to observe and evaluate the
employee’s ability to safely operate the forklift. Both
the training and the evaluation have to be documented.
(Sample on back of this form.)
Is a license or certification required to
operate a forklift?
No. There is no license requirement for forklift operators
but the employer must document that the operator has
completed the following training:
General forklift operation and safety information
(topics listed on the back of this form)
Workplace-specic training, including practice on
the type of forklift the operator will actually be
using (topics listed on the back of this form)
An evaluation of the operator’s skill and ability to
operate the forklift safely. Remember to document
the training!
These topics must be covered when training or evaluating a forklift operator.
Employers must document that employees have been trained and/or evaluated in all the topics listed below.
Use of this checklist for that purpose is optional.
General Forklift Topics
Operating instructions, warnings and precautions
for types of industrial truck the operator will be
authorized to operate.
Differences between the fork lift and an automobile.
Vehicle controls and ins trumentation: w here they
are located, what they do and how they work.
Engine or motor operation.
Steering and maneuvering.
Visibility (including restrictions due to loading).
Fork and at tachment adaptation, operation and
use limitations.
Vehicle capacit y.
Vehicle stability.
Vehicle inspection and maintenance that the
operator will be required to per form.
Refueling and /or charging and recharging of bat teries.
Operating limitations.
Other operating instructions, warnings or precautions
listed in the operator’s manual for the types of vehicles
that the employee is being trained on.
Workplace-Specific Topics
Surface conditions where the vehicle will be operated.
Composit ion of loads to be carried and load stabili ty.
Load manipulation, stacking and unshackling.
Pedestrian t raffic where the vehicle will be operated.
Narrow aisles and ot her restricted places where the
vehicle will be operated.
Hazardous (classified) locations where the vehicle
will be operated.
Ramps and other sloped surfaces that could affect
the vehicle’s stability.
Closed environment s and other areas where
insufficient ventilation or poor vehicle maintenance
could cause a buildup of carbon monoxide or
diesel exhaust .
Other unique or po tentially hazardous
environmental conditions in the workplace that
could affec t safe operation.
Retraining required if changes in workplace
conditions could affect safe operation (such as:
new trenches, new worker access routes or new
staging areas on construction sites).
Name of Operator:
Date of Formal Training: Name of Trainer:
Date of Practical Training: Name of Trainer:
Date of Evaluat ion: Name of Evaluator :
We can help
Employers: We offer workplace safety and health
consultations, risk management assessments,
training and technical assistance at no cost. For more
information, go to Ln i.wa. gov/safety-health/preventing-
injuries-illnesses/request-consultation.
Employee/employee representatives: You may
le a formal complaint when you believe a safety
or health hazard exists in your workplace. Go to
Lni.wa.gov/workers-rights/workplace-complaints/safety-
complaints for information in English and Spanish.
A training program covering general forklift information
is available on the L&I website at Lni.wa.gov /safety-
health/safety-training-materials/online-safety-training.
For more information, visit Lni.wa.gov/safety-health/
safety-topics/search-by-topic and type the word “forklifts”.
Upon request, foreign language support and formats for persons with disabilities are available.
Call 1-800-547-8367. TDD users, call 711. L&I is an equal opportunity employer.
PUBLIC ATION F417-202 -000 [0 6-2021]
29
Visual Check
Tires are inflated and free of excessi
v
e
w
ear or damage. Nuts are tight.
Forks and mast are not bent, worn, or cracked.
Load back rest extension is in place and not bent, cracked, or loose.
Overhead guard is in place and not bent, cracked, or loose.
Attachments (if equipped) operate OK and are not damaged.
Forklift body is free of excessi
v
e lint, grease, or oil.
Hyd
r
aulic oil is full and free of leaks.
Battery connections are tight.
Co
v
ers o
v
er battery and other hazardous parts are in place and secu
r
e.
Load rating plate is present and readable.
Warning decals and operators’ manual are present and readable.
Seat belt or restraint is accessible and not damaged, oily, or dirty.
Motor runs smooth without sudden acceleration.
Horn works.
Turn signal (if equipped) operates smoothly.
Lights (head, tail, and warning) work and are aimed correctly.
Gauges and instruments are working.
Lift and lower operates smoothly without excess drift.
Tilt operates smoothly without excessive drift or “chatter”.
Control le
v
ers are labeled, not loose or binding and freely return to neut
r
al.
Battery charge le
v
el is OK while holding full fo
r
w
ard tilt.
Steering is smooth and responsi
v
e, free of excessi
v
e pla
y
.
B
r
a
k
es
w
ork and function smoothly without g
r
abbing. No fluid leaks.
Parking b
r
a
k
e will hold the forklift on an incline.
Backup alarm (if equipped)
w
orks.
Operator’s Daily Checklist: Gas or LPG Forklift
Check each item before the shift starts. Put a check in the box if the item is OK.
Explain any unchecked items at the bottom and report them to a supervisor.
Do not use an unsafe forklift! Your safety is at risk.
Forklift Serial Number:
Operator:
Hour Meter Reading: Date:
Operator’s Daily Checklist: Electric Forklift
Check each item before the shift starts. Put a check in the box if the item is OK.
Explain any unchecked items at the bottom and report them to a supervisor.
Do not use an unsafe forklift! Your safety is at risk.
Forklift Serial Number:
Operator:
Hour Meter Reading: Date:
Visual Check
Tires are inflated and free of excessi
v
e
w
ear or damage. Nuts are tight.
Forks and mast are not bent, worn or cracked.
Load back rest extension is in place and not bent, cracked or loose.
Overhead guard is in place and not bent, cracked or loose.
Attachments (if equipped) operate OK and are not damaged.
Forklift body is free of excessi
v
e lint, grease or oil.
Engine oil is full and free of leaks.
Hyd
r
aulic oil is full and free of leaks.
Radiator is full and free of leaks.
Fuel level is OK and free of leaks.
Battery connections are tight.
Covers over battery and other hazardous parts are in place and secure.
Load-rating plate is present and readable.
Warning decals and operators’ manual are present and readable.
Seat belt or restraint is accessible and not damaged, oily or dirty.
Engine runs smooth and quiet without leaks or sparks from the exhaust.
Horn works.
Turn signal (if equipped) operates smoothly.
Lights (head, tail, and warning) work and are aimed correctly.
Gauges and instruments are
w
orking.
Lift and lo
w
er ope
r
ates smoothly without excess drift.
Tilt ope
r
ates smoothly without excessi
v
e drift o
r
“chatte
r
.”
Control le
v
ers are labeled, not loose or binding and freely return to neut
r
al.
Steering is smooth and responsi
v
e, free of excessi
v
e pla
y
.
B
r
a
k
es
w
ork and function smoothly without g
r
abbing. No fluid leaks.
Parking b
r
a
k
e will hold the forklift on an incline.
Backup alarm (if equipped)
w
orks.
Appendix A
Appendix A
Revised 04/01/2007
Labor & Industries suggested documentation form
Labor & Industries suggested documentation form
30
Resources
Come to the Source!
Visit www.Lni.wa.gov/Safety for information
on safety and health standards, ergonomics,
WISHA guidelines, hazard alerts, training
workshops, hospitalization and fatalities,
proposed rule changes and safety and
health videos.
Forklift Resources
Find forklift rules, policies, training materials,
videos, hazard alerts and more online at
www.Lni.wa.gov/SafetyTopics. Search for
Forklifts.
31
Get 1-on-1 Assistance
When you need professional help, we’re
here (and we’re free)
As a Washington State business owner, plant
manager or safety ofcer, you’re entitled to
no-cost consultation services from L&I.
L&I’s Division of Occupational Safety and
Health includes safety professionals, industrial
hygienists, ergonomists and risk management
specialists who want to help you protect your
employees and manage your costs.
We’ll work with you to develop a
plan that meets the specic needs of
your business.
Consultants do not issue citations
—
they
help you identify and solve problems.
Visit www.Lni.wa.gov/RiskConsultation
to learn more about the benets of a
consultation and request any or all that
could benet your company.
-
Workplace safety and health
-
Preventing sprains and strains
-
Risk management
Invest in your business and your
employees
Benets of a safe and healthy workplace and
risk management include:
Fewer injuries, lower costs
Less risk of citations during compliance
inspections
Opportunities to lower employee
turnover and improve morale
Peace of mind knowing you have done
your part
Quality of life for employees
Everyone goes home to their loved ones
at the end of the workday.
Schedule your free consultation
Business location Call
Northwest Washington 425-290-1369
King County 206-835-1065
Pierce County/ Olympic
Peninsula
253-596-3917
Southwest Washington 360-575-6951
Central Washington 509-886-6570
Eastern Washington 509-886-6570
Upon request, foreign language support and formats for
persons with disabilities are available. Call 1-800-547-8367.
TDD users, call 711. L&I is an equal opportunity employer. PUBLICATION F417-031-000 [07-2021]
