FORKLIFT OPERATOR

SAFETY TRAINING

Section 4 | Parking & Refueling

Take care when you park a forklift:

Consider the safety of your co-workers.
Never park near walkways or stairways, or in front of an exit.
Lower the forks so they don't create a tripping hazard.

When you will leave the lift unattended and out of your sight, take these precautions: Set the controls to Neutral, set the parking brake, and turn off the engine.

To be really safe, take the key with you.
If the lift is parked on an incline, chock the wheels.

If you park a forklift but stay within 25 feet, and in sight of the lift, you can leave the engine running, but you must lower the forks to the ground, set the controls to Neutral, and set the parking brake.

Always wear the appropriate protective equipment when fueling any kind of forklift. Do not smoke while refueling, and keep any open flames away from refueling areas.

When refueling a propane-powered forklift, follow these steps:

Park the lift and close the fuel line valve on the cylinder. Let the engine run until it stops. This guarantees that the connection hose is empty of propane.
Shut off the ignition.
Put on protective gloves.
Disconnect the hose and the holding straps, and lift the empty cylinder free.
Replace the empty cylinder with a full one. The locating pin should go through the hole in the cylinder handle. When the tank is seated, the relief valve should point straight up, in the 12 o'clock position.
Connect the holding straps.
Tighten the connecting nut.
Slowly open the valve on the cylinder halfway, and check for leaks.
Smell, listen, and look. You can also use a solution of soap and water, and look for bubbles. Never use matches or a flame.
If the valve leaks, tighten the nut, then try to open the valve again, and check for leaks once more.
If the valve continues to leak, change the cylinder. If you still find a leak, have the hose changed or repaired.
Once there are no leaks, slowly open the cylinder all the way.

If you forklift is powered by liquid petroleum gas, or LPG, you refuel by changing cylinders. Wear protective gloves, because contact with liquid propane can cause freeze burn.

Before you begin, close the fuel line valve on the cylinder, but in this case keep the engine running until it stops.

Shut off the ignition. Disconnect the hose and the holding straps, and remove the empty cylinder.

Never use metal tools to change a cylinder. Replace the empty cylinder with a full one in the proper position. The locating pin should engage the hole in the cylinder handle so that the release valve is straight up in the twelve o’clock position.

Connect the holding straps. Tighten the connecting nut. Check the hose to make sure it’s tight. Slowly open the valve on the cylinder part way and check for leaks.

If the valve leaks, tighten the nut and continue. If it still leaks, change the cylinder. And if it still leaks after that, have the hose changed or repaired. Once there are no leaks, slowly open the valve all the way. Secure the cylinder. Start the engine and resume operation.

When you're refueling a gasoline or diesel lift, follow these steps:

Make sure you have the proper fuel.
Turn off the engine and set the parking brake.
Don't overfill the tank. Replace the fuel cap and clean up any spilled fuel.

Start the engine and continue.

Wear eye and skin protection when changing a battery—battery acid is corrosive! Follow these steps when changing a battery:

Set the forklift parking brake and shut off the engine.
Make sure the battery is secure before lifting it.
Stay clear of the battery when moving it.

When charging a forklift battery, wear protective eyewear and skin protection, and know the location of the nearest eyewash station or shower. Also know where to find materials for neutralizing spilled electrolyte.

Be sure the ventilation system is working before charging a battery.
If the battery is on the forklift, uncover the battery compartment to prevent a build-up of heat or hydrogen gas.
Make sure the vent caps are not plugged.
Turn the charger off before connecting it to the battery.
Don't let any metal objects come in contact with the battery terminals.
Carefully clean up any spilled electrolyte using proper safety procedures.

When adding water to top off a battery, be sure to wear safety goggles to protect against electrolyte splash or spray. A face shield is even better.

If you dilute concentrated sulfuric acid with water to make battery acid, remember to always add the acid to the water. Adding water to acid can esult in a dangerous chemical reaction. Wear eye and skin protection when changing a battery—battery acid is corrosive! Also know where the eyewash station and the shower are, and supplies for cleaning up hazardous spills. Follow these steps when changing a battery:

Set the forklift parking brake and shut off the engine.
Make sure the battery is secure before lifting it.
Stay clear of the battery when moving it.

When adding water to top off a battery, be sure to wear safety goggles to protect against electrolyte splash or spray. A face shield is even better.

Be sure the ventilation system is working before charging a battery.
If the battery is on the forklift, uncover the battery compartment to prevent a build-up of heat or hydrogen gas.
Make sure the vent caps are not plugged.
Turn the charger off before connecting it to the battery.
Don't let any metal objects come in contact with the battery terminals.
Carefully clean up any spilled electrolyte using proper safety procedures.

Be sure the ventilation system is working before charging a battery.
If the battery is on the forklift, uncover the battery compartment to prevent a build-up of heat or hydrogen gas.
Make sure the vent caps are not plugged.
Turn the charger off before connecting it to the battery.
Don't let any metal objects come in contact with the battery terminals.
Carefully clean up any spilled electrolyte using proper safety procedures.

GO TO NEXT SECTION

Introduction | Welcome to Forklift Safety Training

Section 1 | Forklift Basics and Inspection

Section 2 | Driving, Lifting, and Placing

Section 3 | Trucks, Trailer, and Rail cars

Section 4 | Parking & Refueling

Section 5 | Special Units and Maintenance

Section 6 | Conclusion