ABB Ltd: Safety Management System SWI/059
Issued by Department: Date: Language: Register No.: Revision: Page:
GBPT Service/Comp 07/2006 en N/A Page 1 of 5
SAFE USE OF FORK LIFT TRUCKS
THE TASK
Fork lift trucks are essential to many businesses and are both efficient and cost effective. But they
can also be lethal weapons that can kill or cause serious injury if not used correctly by trained
operators.
Most of our locations have Fork lift trucks and we have approx 35 trained operators, all should
ensure they are familiar with this safety work instruction.
THE HAZARDS
See separate Risk Assessments PFI 206RA, T&DSRA022 and RA016
SAFE METHOD OF WORKING
1. PLANNING
The supervisor will ensure that full details of the tasks to be carried out are available, and clear
instructions and information are provided to, and understood by, the person doing the work.
ALL PERSONS MUST BE TRAINED AND AUTHORISED TO DRIVE ANY FORK LIFT
TRUCK.
2. EQUIPMENT.
All Fork Lift Trucks are part of ABBs regular planned maintenance procedures and are regularly
inspected and tested by an independent Insurance Company to comply with the Lifting Operations
and Lifting Equipment Regulations 1998. Copies of certificates can be obtained from the
compliance department.
3. WORK SEQUENCE.
3.1 Before work commences, ensure that the weekly Fork Lift Truck inspection has been carried
out in accordance with the ABB procedure ‘Pre-use Inspection Checklist’ (QF/SAF/050) as per
the information posters displayed locally (QF/SAF/051).
If an inspection has not been carried out by one of your colleagues within the last week, YOU
MUST CARRY OUT THESE CHECKS AND RECORD ON THE CHECKLISTS PROVIDED.
ANY DEFECTS MUST BE REPORTED TO YOUR SUPERVISOR.
DO NOT OPERATE THE FORK LIFT TRUCK IF PRE-USE INSPECTION IS OVERDUE.
3.2 Familiarise yourself with the local risk assessment that is in place and displayed, and
carry out an on-site specific risk assessment (if required) to record any additional hazards not
addressed. Apply additional control measures as required
“This document is a computer resident / maintained version,
any paper copy containing this note is uncontrolled”
ABB Ltd: Safety Management System SWI/059
Issued by Department: Date: Language: Register No.: Revision: Page:
GBPT Service/Comp 07/2006 en N/A Page 2 of 5
3.3 Seat belts – If a seat belt is fitted, use it. The law requires the provision of restraining
systems to prevent crushing of the operator between truck and ground if there is a foreseeable risk
of overturning (e.g. uneven ground).
3.4 From your training understand the limits of the truck you are to operate with regard to :
• Rated Capacity – See the rating plate on the truck
• Load Centre – See the load centre plate on the truck
• Stability – A truck is at its most stable when being driven:
o In a straight line
o At a sensible speed
o On even ground
o With the load being carried as low as practically possible – the higher the load
the more unstable
o With the pallet in contact with the forks heels and stabilising back tilt applied –
this puts the centre of gravity as far back as possible to aid the stability of the
truck and load. It also reduces the overall length of truck and load to aid
manoeuvring.
• Observe the principles of counterbalance – the centre of the front wheel on a fork lift
truck is like the balance point on a see-saw, the weight of the load on one side is balanced
by the weight of the truck on the other.
• Lengthwise instability can be caused by:
o Overloading
o Braking harshly
o Accelerating harshly
o Incorrect use of hydraulics and tilt
o Undercutting – bring the forks right up to the fork heels
o Live loads - Do not allow loads to swing
o Ground conditions
• Sideways instability can be caused by:
o Turning at speed
o Travelling across a slope
o Flat or damaged tyres
o Live loads
o Carrying a load off centre
o Ground conditions
Using Attachments
o All attachments must be suitable for the truck
o In good condition
o Securely attached
Common types include –
Side shift – (As on the Rugby FLT)
o Always centralise after use
o Make sure loads are transported with the forks centralised
Reel clamps or drums attachments
o Sides of the clamp are shaped to the load
Fork Extensions
o Must be inserted at least two thirds of the way into the load
“This document is a computer resident / maintained version,
any paper copy containing this note is uncontrolled”
ABB Ltd: Safety Management System SWI/059
Issued by Department: Date: Language: Register No.: Revision: Page:
GBPT Service/Comp 07/2006 en N/A Page 3 of 5
3.5 Battery Care and charging - Main dangers are:
o Electricity – Use correct charger, insulated tools, remove jewellery, connect
charger to the truck before switching on the electricity supply, disconnect
electricity supply before disconnecting the charger from the supply, Isolate all
mains supply before starting maintenance.
o Sulphuric Acid – Wear appropriate safety equipment e.g. rubber gloves,
goggles, apron. If acid comes into contact with the skin wash off with plenty of
water, do not overfill batteries, clean up any spillages.
o Hydrogen and oxygen (explosive) – Do not smoke whilst handling or charging
batteries, expose battery whilst charging to let gasses escape, remove jewellery
and use insulated tools, use distilled or de-ionised water only for topping up.
3.6 Refuelling – To change propane cylinders:
o Park in a designated safe refuelling area
o Close the gas valve and allow the engine to run until it dies
o Turn off engine and remove the key
o Disconnect the fuel line from the gas bottle
o Release the gas bottle securing straps and remove the empty bottle
o Store the empty bottle in its designated area
o Replace with a full bottle and secure in position, ensuring arrow on the bottle
base is pointing downwards. (Two man lift)
o Reconnect the fuel lines to the gas bottle
o Open the gas bottle valve
Diesel / Petrol powered trucks
o Refuel only at recognised refuelling points
o Park correctly
o Switch off engine
o Fill with correct fuel
o Do not overfill, leave room for expansion
o Replace cap securely
o Clear away any spills
3.7 Safe Driving
o Be sensible and obey the rules - Never carry passengers, no horseplay,
obey all signs and travel direction restrictions.
o Keep a look out – Look carefully around before moving off, look in direction of
travel, ensure sufficient clearance before raising loads, ensure sufficient
overhead clearance for doorways, pipes, lights etc, watch out for pedestrians.
o If you can’t see – drive in reverse, use a banksman, when approaching a
corner, slow down, and be prepared to stop, sound a warning.
o Stay in control – Watch your speed, when crossing bumps etc cross
diagonally one wheel at a time
o Park properly – Remove keys when not in the truck to prevent unauthorised
use, don’t cause an obstruction, keep away from blind spots, doors, loading
bays etc, don’t park on a slopes
o Operate correctly – Lift loads correctly, operate hydraulics smoothly, do not
push or drag loads, don’t use defective pallets.
o Take care of yourself – Don’t allow any part of your body to protrude out of
the cab whilst in operation, when mounting or dismounting face the truck, use
hand grips, look around for hazards, do not jump on and off.
o If your truck is about to tip over – DO NOT JUMP, HOLD ON TIGHTLY
“This document is a computer resident / maintained version,
any paper copy containing this note is uncontrolled”
ABB Ltd: Safety Management System SWI/059
Issued by Department: Date: Language: Register No.: Revision: Page:
GBPT Service/Comp 07/2006 en N/A Page 4 of 5
3.8 Drink and Drugs – The law considers a fork lift truck to be a motor vehicle, this means that
an operator who is found to be operating a truck whilst under the influence of drink or drugs can be
prosecuted. This doesn’t just apply to the public highway but to factories and warehouses as well.
3.9 Public Highways – Trucks must be registered and licensed for use on the public roads,
insurance is required, trucks must have number plates on the rear or on both sides, the driver must
have a full driving licence, appropriate lighting is required.
PERSONAL PROTECTIVE EQUIPMENT
During the use of fork lift trucks, operators shall wear company work wear, safety footwear and a
high visibility jacket or waistcoat at all times.
MONITORING
The team supervisor, facilities manager and Safety Advisors will check that safe methods of fork lift
truck operations are being employed during site visits.
REFERENCE INFORMATION
When carrying out this task, further reference may be made to: -
Health and Safety at Work Act 1974
Management of Health and Safety at Work Regulations 1999
Approved code of practice and Guidance (ACOP) L117
Provision and use of work equipment regulations 1998 (PUWER)
Lifting operations and Lifting equipment regulations 1998 (LOLER)
“This document is a computer resident / maintained version,
any paper copy containing this note is uncontrolled”
ABB Ltd: Safety Management System SWI/059
Issued by Department: Date: Language: Register No.: Revision: Page:
GBPT Service/Comp 07/2006 en N/A Page 5 of 5
5.0 Revision History
Page (P) Description Date
Rev. Chapt. (C) Dept./Init
- All Initial Issue 07/06 Compliance
“This document is a computer resident / maintained version,
any paper copy containing this note is uncontrolled”
