As operations get busy, it can be easy for safety to fall to the wayside in the hopes of saving a few extra minutes. However, lax safety precautions can lead to catastrophic accidents. As business owners and managers, it’s important to stay vigilant during the busy season to ensure operations continue running smoothly and employees stay safe on and around material handling equipment.

By taking a few extra minutes to review safety essentials with the team, you can prevent forklift accidents. Below are three important forklift safety tips to keep top-of-mind.

1.    Complete a Thorough Check of Equipment Before Each Use. Many forklift issues can be mitigated by routine, detailed equipment checks that include identifying leaks in fuel lines, inspecting propane cylinders for rusting or dents, and removing excess oil and grease. When a problem arises, management can address and make repairs in short order, instead of letting small problems go unnoticed until they’ve escalated to the point of costly repairs.

2.    Enforce Safe Operation Guidelines.

Many accidents and problems can be easily avoided by enforcing safety measures among all employees, not just those operating forklifts.  

PPE — Forklift safety precautions apply not only to the operator, but to those around them on the warehouse floor, in the loading dock, and throughout a terminal. It’s important for everyone to wear proper personal protection equipment (PPE) such as hard hats, protective footwear, eye protection and high-visibility clothing.

Buckle Up & Know Your Weight Capacity — Overturned forklifts are one of the leading causes of forklift-related accidents, so it’s critical to emphasize the importance of buckling up and staying within the designated weight capacity. Weight capacity markings are there for a reason — to keep operators safe. Exceeding the weight capacity of a forklift significantly increases the risk of tipping.

Use the Horn & Mind Ramps — Once a forklift is ready for work, operators must move slowly and use the horn. When vision is obstructed, it’s easy to have a collision. Using the horn at every intersection will keep pedestrians and other operators safe. Drivers should always carry a load pointing up an incline with their head pointed in the direction they are going. If unloaded, keep the forks pointed downgrade.  

Brakes — When finished operating a forklift, it’s important to always lower the forks, use the parking brake, and set the controls to neutral. Safely parking the machine reduces the risk of unintended movement and injury. If parking on an incline, be sure to use wheel blocks to secure the machine further.  

3.    Know Your Energy Source Specifications.

Each forklift model has its own set of safety procedures, which is why it’s important to read the manual and stay up to date on recalls and maintenance. Additionally, each energy source has its own set of safety precautions to be aware of. As one of the most common energy sources used to power forklifts, propane has been the powerhouse of the material handling industry for decades.

Fortunately, propane forklifts are safe to use both indoors and outdoors. Best-in-class propane forklift engines can produce 97% fewer hydrocarbon (HC) and nitrogen oxide (NOx) emissions when compared with similarly sized diesel forklift engines, preventing operators from breathing in dirty diesel fumes. When operating with propane, it’s important to keep the following tips in mind.

Inspect cylinders before operation — Check cylinders for rusting, dents, gouges, and leaks. Cylinders that show signs of wear or leaks shouldn’t be used and may need to be replaced, even if within the cylinder’s requalification date. Confirm the cylinder valve is closed before connecting.

Use proper lift techniques to place a cylinder onto a forklift — The cylinder should be carefully placed into the cradle so that the cylinder pin enters the locating hole in the cylinder collar. Once it is properly situated, secure the cylinder by tightening the brackets, and check for leaks using a leak detection solution. 

Secure the pressure relief valve on the cylinder — Operators should check that the pressure relief valve fitting is roughly 180 degrees from the forklift’s locating pin. Firmly tighten the gas line to the service connection. 

Close the service valves on cylinders when not in use — This helps prevent potential injury around internal combustion engines and unintended fuel loss.

Store propane cylinders in a secure rack or cage — Cylinders should be stored horizontally, with the pressure relief valves in the uppermost position, and operators should use proper lifting techniques when removing cylinders from storage and placing onto a forklift. A propane cylinder storage rack should be located a safe distance from heat or ignition sources, away from stairwells and high traffic areas, and protected from exposure to the elements.

Fortunately for crews operating with propane-powered forklifts, they can rely on their local propane supplier for safety training and refueling support. Regardless of the refueling option, propane suppliers will inspect forklift cylinders each time they’re exchanged and remove damaged cylinders from service. They will also replace or fix broken parts. Suppliers often offer additional safety training opportunities for customers to ensure all employees understand how to install propane cylinders and utilize refueling equipment properly.

While it may seem obvious, regular and simple safety reminders can make the difference between a smooth-running day and an avoidable accident.

Jim Bunsey is senior manager of safety and compliance at PERC.