Today, we’re going to talk about rough terrain forklift safety. Rough terrain forklifts are essential material handling equipment on many worksites. These powerful workhorses can handle very heavy loads and operate on all kinds of difficult terrain.

Because of the nature of their work and the environments in which they operate, using rough terrain forklifts can also pose numerous hazards. And that’s why we’re here today—to review the hazards and explain what you can do to prevent accidents and injuries when operating these lift trucks.

Session Objectives

The main objective of this session is to discuss rough terrain forklift safety. By the time this session is over, you should be able to:

• Identify rough terrain forklift hazards;
• Understand stability principles;
• Follow basic safety rules;
• Inspect forklifts and worksites for safety;
• Load, unload, and travel safely; and
• Prevent tip overs.

Pre-quiz True or False?

Before we begin the session, let’s take a few minutes to see how much you already know about rough terrain forklifts. Decide whether each statement on the screen is true or false.

• Most rough terrain forklift accidents are caused by operator error— This is true.
• The weight of the load does not affect stability error—This is false.
• Anyone who has driven an all-terrain vehicle is permitted to operate a rough terrain forklift—This is false.
• You should check weight charts when loading—This is true.

How did you do? Did you get all the answers right?

If not, don’t worry. You’ll learn all about these issues and a lot more during the session.

Features

• Rough terrain forklifts are versatile material handlers that are used to handle all kinds of materials in a variety of work situations. They are used in construction, lumber yards, mining operations, landscaping, agriculture, loading and unloading railcars, and other outdoor work where the forklift has to be able to handle unpaved surfaces, disturbed ground, and other difficult terrain that a regular forklift could not handle safely.

Heavy-duty construction and large tires with deep treads make it possible for these trucks to carry thousands of pounds of material over rugged surfaces. Powered by an internal combustion engine that operates on gasoline, diesel, or propane, they have plenty of power and speed.

Features such as telescoping booms allow these these forklifts to lift large loads high to stack and remove materials, which makes them especially useful for many different worksites.

Think about the many benefits of rough terrain forklifts.

Hazards

Although rough terrain forklifts are versatile and extremely useful, they can also be hazardous in a number of ways. Hazards include:

• Tipovers and rollovers;
• Collisions with other vehicles or collisions with workers on the site;
• Slopes and edges;
• Dips, holes, trenches, and excavations;
• Confined areas such as narrow aisles; and
• Ground and overhead obstructions.

Think about potential hazards you could encounter while operating a rough terrain forklift.

Accidents

Most rough terrain forklift accidents are the result of operator error.

Errors may include:

• Visibility issues, such as not having a clear line of sight in the direction of travel;
• Inattention while driving;
• Failure to warn other vehicles or pedestrians;
• Overloading the forklift;
• Improperly loading or unloading the forklift;
• Misjudging terrain;
• Failure to inspect or maintain the forklift properly; and
• Failure to obey site traffic rules.

Stability

• The center of gravity of an unloaded forklift is just below the operator’s seat. Having the forklift’s weight balanced over the center of gravity helps keep the forklift stable and prevents tipovers.
• However, with a load, the center of gravity shifts. As long as the center of gravity remains inside a triangular area formed by the front wheels and the center of the rear axle, the forklift is stable and won’t tip over.
• This triangular area is known as the stability triangle. If you draw a line between the front wheels and then a line back from each wheel to the center of the rear axles, you can clearly see the stability triangle.

Adding a load and then raising the forks causes the center of gravity to shift toward the base of the triangle. If the load is too heavy or poorly balanced, the center of gravity can shift outside the stability triangle, and the forklift is likely to tip over.

Make sure you understand the stability principles involved in keeping rough terrain forklifts upright and preventing tipovers.

Conditions that Affect Stability

Conditions that can affect stability include:

• Ground conditions;
• Speed of travel;
• Grade;
• Load;
• Tire inflation; and
• Operator skill, knowledge, and judgment.

Inspection Checklist: Worksite

Before operating a rough terrain forklift, you should always conduct a brief but careful inspection of the equipment. Items to check include:

• Operating controls and brakes;
• Lights, horn, and backup alarm;
• Gauges and indicators;
• Tire condition and pressure;
• Engine fluids, hoses, and belts;
• Safety belts;
• Automatic shutoff;
• Forks, tilt mechanism, mast or boom; and
• Hydraulic cables and connections.

Do not operate a forklift that is not in safe condition. Report problems to a supervisor immediately, and make sure no one else uses the forklift until it is fixed.

What other items do you inspect before you operate a forklift?

Inspection Checklist: Worksite (cont.)

You should also inspect the worksite before you begin operating a rough terrain forklift, and look for possible hazards. For example, you should check for:

• Hazardous ground/soil conditions;
• Water hazards;
• Electric power lines and other overhead obstructions;
• Slopes and edges;
• Ground hazards such as culverts, excavations, trenches, holes, and dips;
• Line-of-sight and areas of obstructed visibility;
• The possibility of hazardous weather;
• Confined areas and maneuverability issues; and
• Speed restrictions.

Think about other site hazards you should look for before you begin working.

Basic Safety Rules

One of the most important contributions you can make to worksite safety and to your own safety is to follow safe operating procedures when driving a rough terrain forklift. For example:

• Only operate a rough terrain forklift if you are trained and authorized;
• Make sure controls are operating properly;
• Check back-up alarm and horn to be sure they are working properly;
• Use a signal person at a safe distance on the ground when you can’t see clearly while backing or maneuvering; and
• Wear a seat belt at all times when operating the fork truck.

Basic Safety Rules (cont.)

Additional safe operating procedures include the following:

• Don’t allow anyone to stand or pass under the elevated portion of a fork truck, whether empty or loaded.
• Don’t allow any riders on the equipment.
• Don’t park the fork truck on an incline. If you must park on an incline, block the wheels.
• Don’t leave the fork truck unattended unless it is properly shut down and parked. The truck is unattended when the operator is 25 feet or more away and in view, or at anytime the truck is not in view of the operator.
• Finally, lower the boom, shut off the engine, and engage the parking brake when exiting the operator’s station.

Can you think of other safe operating procedures you should follow? Make a list of the suggestions in this and the previous slide and the other procedures you’ve thought of.

Stability Review: Make the Right Choice

Let’s take a few minutes now to test your memory about what we’ve discussed concerning stability principles. See if you can answer these three questions on the screen.

• To prevent tipovers, where should the center of gravity be in relation to the stability triangle? The answer is: Inside triangle (a).
• The stability triangle is formed by the two front wheels and the center of rear axle (b).
• How does adding a load affect the center of gravity? Adding a load causes the center of gravity to shift toward the front edge of the triangle (a).

How did you do? Did you get all the answers right?

Review

Now it’s time to ask yourself if you understand all the information presented so far. For example, do you understand what we’ve said about rough terrain forklift:

• Features?
• Hazards?
• Stability principles?
• Inspection procedures?
• Basic safety rules?

It’s important to understand all this information so that you can operate rough terrain forklifts safely.

Let’s continue to the next slide and talk about safe loading procedures.

Loading

Loading a rough terrain forklift properly is extremely important to safe operation. An incorrectly loaded forklift is unstable and could tip over or drop its load. Remember these basic rules for loading:

• Check weight charts so that you don’t exceed the rated load of the machine or the forks;
• Set the forks wide and make sure they’re level;
• Slowly slide the forks completely under the load. In some cases, it may be necessary to inspect the load to ensure it’s secure before moving the forklift;
• Center the load and position it so that it just touches the backrest;
• Tilt back the mast;
• Finally, lift the load, tilting it back a little more before traveling and making sure the load is secure.

Think about the steps you must take to make sure you load a rough terrain forklift properly.

Unloading onto the Ground

Unloading correctly is equally important. Follow these basic steps when unloading onto the ground:

• Make sure there are no pedestrians in the unloading area;
• Position the load directly over the destination;
• Apply the brakes slowly—ensure the forks are no longer supporting the load;
• Straighten the mast;
• Slowly lower the load;
• And finally, back away slowly, making sure the forks are clear before turning.

Unloading onto Trucks or Railcars

When unloading onto a truck:

• Make sure the trailer’s rear wheels are chocked and the truck’s brakes are locked, or that the railcar is properly secured so that it can’t move;
• Maintain a safe distance from the edge of ramps, platforms, or other work surfaces;
• Position load;
• Apply the brakes slowly—ensure the forks are no longer supporting the load;
• Tilt the load forward and lower; and
• Back away slowly, checking behind for clearance.

Unloading onto Stack or Rack

When unloading onto a stack or a rack:

• Raise load to the correct height;
• Move it slowly into position;
• Apply brakes;
• Tilt the load forward;
• Lower load onto the rack or stack;
• Retract the boom; and
• Pull the forks back slowly, and check clearance before turning.

Think about the proper procedures for unloading onto the ground, trucks, and racks or stacks.

Traveling

You must also take proper precautions when traveling, with or without a load. Remember these basic rules:

• Look in the direction of travel and maintain a clear line of sight;
• Accelerate gradually and back up slowly, especially when carrying a load;
• Take care when traveling on uneven ground and slopes;
• Keep the boom and load as low as possible when traveling;
• Maintain proper clearances from power lines and other overhead obstructions;
• Finally, be careful when operating in confined areas like narrow aisles so that you don’t hit any structures or people.

Traveling (cont.)

• Obey speed limits, signs, flags, and markings, and watch out for other vehicles and pedestrians;
• Give pedestrians the right of way;
• Check mirrors frequently;
• When near congestion or a blind corner, always use your horn to ensure that your presence is known;
• Avoid sharp turns, especially when fully loaded; and
• Stop, look, and listen before crossing roads or railroad tracks.

Think about the rules you are required to follow when driving a rough terrain forklift around the worksite.

Causes of Tipovers

Common causes of forklift tipovers include:

• Exceeding the load capacity of the forklift;
• Collisions with other trucks or pedestrians;
• Excessive speed when turning, or turning on an inclined or uneven surface;
• Getting too close to an edge;
• Traveling with the load raised too high;
• Turning or braking suddenly with a raised load;
• And, tilting a raised load too far forward.

Think about a tipover or rollover accident you have seen or heard about. What caused this accident?

Preventing Tipovers

Here are some tips for preventing tipovers:

• Never exceed the load capacity of a forklift.
• Take turns slowly, and never turn on a ramp.
• Make sure the load is always facing uphill when going up or down inclines.
• Keep forks low and load tilted back when traveling.
• Watch out for dips, holes, rocks, and other obstructions.
• Don’t brake suddenly with load raised.

Think about the steps you need to take to prevent tipovers.

In the Event of a Tipover

In the event of a tipover:

• Never jump;
• Stay seated;
• Keep your seat belt on;
• Firmly hold on to the inside frame;
• Lean away from impact; and
• Brace for impact.

Caution

Rough terrain forklifts should generally not be used for lifting people. If, however, this must be done, it must be done safely. This means:

• Securely attaching a platform with guardrail to the lifting carriage and forks;
• Making sure personnel being elevated wear a harness and lanyard that is attached to the platform guardrail;
• Remaining in the operator station while workers are elevated;
• Never moving the forklift while workers are elevated;
• Making sure elevated personnel do not climb on guardrails or use ladders, planks, railings, or other materials to gain more height or reach;
• Using a spotter to ensure the personnel on the platform are safe.
• And finally, raising and lowering the platform slowly and smoothly, checking for overhead obstructions.

Only use a rough terrain forklift to lift personnel if necessary and if you are trained and authorized to perform this procedure. Also make sure personnel involved are properly briefed and equipped to prevent falls.

Exercise

Now let’s take a few minutes to review the common causes of tipovers.

Your job here is to decide which item you think could possibly cause a tipover.

How did you do? Did you get all the right answers?

Let’s review your choices briefly. Possible causes of a tipover include:

• Exceeding load capacity;
• Excessive speed when turning;
• Traveling with load raised too high; and
• Braking suddenly with load raised.

Review

Let’s review the information presented in the previous slides now by asking if you understand all the points we’ve covered? Do you understand:

• Safety procedures for loading and unloading?
• Traveling safely?
• Causes of tipovers?
• Preventing tipovers?
• What to do in the event of a tipover?
• Lifting personnel safely?

You need to understand all of this information in order to operate a rough terrain forklift safely.

Now let’s conclude the session with some key points to remember.

Key Points To Remember

Here are the main points to remember from this session on rough terrain forklift safety:

• Operating a rough terrain forklift exposes you to many hazards.
• You must know how to safely load, unload, and drive a rough terrain forklift to prevent accidents and injuries.
• You have to understand stability principles as well as how to prevent tipovers.
• Never operate a rough terrain forklift unless you are trained and authorized.

This concludes the introduction to the rough terrain forklift safety training session.