Analysis of Forklift Accident Patterns [Daily Question 20090413]

I have seen cases where the products were stacked too high (above 2.5 meters), and when the forklift lifted them, the inclination angle caused the products to fall and hit the driver. I’ve also seen cases where vehicles reversing knocked down walls.

1. Working without a license. Forklifts are motorized vehicles and fall under the category of special types of work; drivers must possess the appropriate driving qualifications as well as skills in maintenance, and they must pass examinations conducted by the relevant authorities to obtain a license before they are allowed to work. However, some companies often appoint employees on a temporary basis and use unqualified individuals as operators; without receiving any training or passing any examinations mandated by the relevant authorities, these individuals start working by simply accompanying the drivers for a few days before being allowed to operate the equipment themselves. As a result of their lack of skill, mistakes occur frequently during loading and transportation, leading to accidents. 2. Working while sick. Due to busy production schedules, heavy workloads, or a desire to avoid hassle and save costs, technical repairs and inspections have not been carried out for a long time. Additionally, drivers often lack a strong sense of responsibility, as well as the necessary skills for maintenance. As a result, the forklifts develop problems such as broken or non-functional headlights and brakes, loss of control over the steering wheel, a non-working horn, slipping tires, oil leakage from the gearbox, and low water levels in the radiator. In such cases, drivers keep pushing the forklift forward regardless of these issues, until an accident occurs. 3. Excessive speed. The roads within the factory are narrow, there are many vehicles and people, as well as numerous intersections. According to the \"Regulations on Safety Management in Chemical Enterprises,\" the speed at which motor vehicles should travel within the factory is 5 km/h when turning, and 10–15 km/h on straight roads. However, the vast majority of forklifts exceed these speed limits while in use. In situations where an emergency arises ahead, drivers become panicked, which results in the forklift tipping over, causing injuries and property damage. 4. Overload transportation. When loading goods, in pursuit of speed and convenience, shipments are often loaded to excessive heights, widths, and weights ； When transporting large items, there is no one to provide guidance ； Failing to tie down extremely top-heavy items securely when transporting them ； Even more recklessly, when exceeding the forklift’s own loading capacity, they operate by increasing the weight at the back of the vehicle, engaging in reckless handling. 5. Mixing people and goods. When lifting and lowering objects at heights, workers, for convenience, use forklifts to climb up and down ； When transporting materials, loading and unloading staff travel along with the vehicle ； It is common to see incidents such as handlers getting their hands crushed or falling from forklifts. 6. Transporting hazardous chemicals recklessly. With small wheels and a narrow spacing between them, such vehicles are prone to jolting and shaking. In pursuit of convenience and to save effort, loaders and unloaders take the risk of transporting flammable, explosive, or highly corrosive hazardous chemicals over long distances. These chemicals are neither properly tied down nor sealed, resulting in them shifting around during transport, possibly spilling or colliding, leading to loss of materials and posing a danger to pedestrians. 　

Causes and types of forklift accidents: Accidents that occur during forklift loading and unloading operations in factories mostly happen during these processes. The main types of such accidents are overload during loading or unloading, which causes the vehicle to lose its longitudinal balance, leading to it tipping over or shifting suddenly and injuring people； Items carried on forks roll off and strike, causing injuries to people ； Forklift bucket injures person ； Loading, degenerative injuries to people, etc. Precautions for forklift accidents: 1. Only drivers who have received training and hold a driving license may operate the forklift ； 2. Check all control and alarm devices before driving; if any damage or defects are found, operate the vehicle only after they have been repaired ； 3. When transporting, the specified load limit must not be exceeded; the forks must be fully inserted under the goods, and the goods should be evenly distributed across the forks. It is not allowed to lift the goods using just the tip of a single fork ； 4. Start, turn, drive, brake, and stop smoothly; reduce speed when turning on wet or smooth roads ； 5. When driving with cargo, lower the load and tilt the mast backward ； 6. When driving on slopes, proceed with caution. On slopes steeper than 10%, drive forward when going uphill and backward when going downhill; do not turn while on an uphill or downhill slope. Do not perform loading or unloading operations while the forklift is in motion ； 7. While driving, be aware of pedestrians, obstacles, and potholed roads, as well as the space above the forklift ； 8. It is not allowed for people to stand on the forks, and the vehicle must not carry passengers ； 9. It is not allowed for anyone to stand under the forks or walk beneath them ； 10. It is prohibited to operate the vehicle and its attachments from any position other than the driver’s seat ； 11. Do not move goods that are not secured or piled loosely; be careful when handling larger-sized goods ； 12. For high-rise forklifts with a lifting height of more than 3 meters, care should be taken to prevent goods above from falling; protective measures must be taken if necessary ； During operation, the boom should be tilted backward as much as possible, with tilting forward and backward being kept to a minimum ； 13. When adding fuel, the driver should not be in the vehicle and the engine must be turned off; do not start the engine when checking the battery or fuel tank level ； 14. When leaving the vehicle, lower the forks to the ground, place the gear lever in neutral, turn off the engine and disconnect the power supply, and engage the handbrake. When parking on a slope, it is also necessary to use blocks to support the wheels.

Recently, we had an accident here: an unlicensed person tried to operate a forklift without permission, fell off the vehicle, and was killed by the forklift itself!

The forklift driver at our company is driving the forklift and doing drift! I don’t know how many times I’ve had to say it – they just won’t listen! (Young man) Could everyone send over a few pictures! Let me teach him a good lesson!

While operating a forklift to transport steel coils, and just as he was about to place the coils on the shelves, the forklift suddenly moved forward about 20-30 centimeters, hitting the head of a person who was working alongside him and crushing him between the shelf pillar and the forklift. Yao died despite efforts to save him due to the severity of his injuries. While operating the forklift to lift a load, the rear idler tire (steering tire) turned sideways, causing the front drive tire to slip and wear out severely. The bolts connecting the front axle to the fork frame came loose, resulting in the load falling in the left front part of the vehicle (the weight of the load was 3.1 tons). The front fork frame collapsed towards the driver’s cabin, pressing on the driver’s head and chest; despite efforts to save him, he died. The driver operated a forklift without a license and carried passengers in violation of regulations; when the vehicle turned, it overturned, crushing the passengers, who died despite efforts to save them at the hospital.

There are many causes of forklift accidents, which can be analyzed from three aspects: the maintenance of the forklift itself, the precautions to be taken by forklift operators, and the precautions during loading and unloading operations. Forklift maintenance: To ensure the forklift operates properly and reliably and to fully utilize its potential, regular maintenance is necessary. Technical maintenance measures generally include: 1. Routine maintenance, after each shift of work. 2. Level 1 technical maintenance is required after 100 hours of cumulative operation; for a single-shift work schedule, this corresponds to 2 weeks. 3. Secondary technical maintenance is required after 500 hours of cumulative operation; for a single-shift work schedule, this corresponds to one quarter. I. Routine Maintenance 1. Clean the forklift of dirt, mud, and dust; the key areas to focus on are: the fork frame and mast slides, the generator and starter, the battery terminal posts, the water tank, and the air filter. 2. Check the tightening of all components, with a focus on: the fork frame supports, the screws used to tighten the lifting chains, the wheel screws, the wheel fixing pins, the brakes, and the screws of the steering mechanism. 3. Check the reliability and flexibility of the steering gear. 4. Check for leaks, with a focus on: all pipe joints, the diesel tank, the oil tank, the brake pump, the lifting cylinders, the tilting cylinders, the water tank, the water pump, the engine oil pan, the torque converter, the transmission, the drive axle, the main reducer, the hydraulic steering gear, and the steering cylinders. 5. Tire pressure check: If it is insufficient, fill it to the specified value and ensure there are no leaks. Check the tire contact surface and sides for any damage, and whether the rim is deformed. 6. Brake fluid and water level check: Check whether the brake fluid is within the specified range, and verify that there is no air mixed in the brake lines. When adding brake fluid, prevent dust and water from entering. When filling the water tank, use clean tap water; if antifreeze is used, the same antifreeze should be added. Do not open the water tank lid when the water temperature is above 70°C. When opening it, place a thin cloth under it, and do not turn the lid using gloves. 7. Check of engine oil level, hydraulic fluid level, and electrolyte level: First, remove the oil dipstick, clean its tip, reinsert it, and then pull it out to check whether the oil level is between the two marks. The oil level in the working oil tank should be between the two scale lines ； Too little oil will cause air to enter the pipes, while too much will overflow from the cover. The battery electrolyte level should also be between the upper and lower marks; if it is too low, distilled water should be added until it reaches the upper mark. 8. Inspection of the brake pedal, foot pedal, clutch pedal, and handbrake: Press each pedal to check for any abnormal slowness in response or sticking. The force applied to the manual control lever should be less than 300 N, to ensure that the manual brake is safe and reliable. 9. Inspection of belts, horns, lights, instruments, etc.: Check whether the tension of the belts is within the specified range; if there is no room for adjustment or if the belts are damaged or cracked, they must be replaced ； The horn, lights, and instruments should all be in good working order. 10. Place the oil filter sediment there. II. Level 1 technical maintenance is carried out in accordance with the “daily maintenance” tasks, with the addition of the following work. 1. Check the cylinder pressure or vacuum level. 2. Check and adjust the valve clearance. 3. Check whether the thermostat is working properly. 4. Check whether the multi-way directional valve, lifting cylinder, tilting cylinder, steering cylinder, and gear pump are operating properly. 5. Check whether the transmission shifts properly. 6. Check and adjust the clearance between the brake pads and the brake drums of the hand and foot brakes. 7. Replace the oil in the oil pan, check whether the crankcase ventilation pipe is in good condition, and clean the oil filter and diesel filter elements. 8. Check whether the generator and starter motor are securely installed, and whether the wiring connections are clean and firm; also inspect the carbon brushes and commutator for any signs of wear. 9. Check the tightness of the fan belt. 10. Check whether the wheels are securely installed, whether the tire pressure meets the requirements, and remove any debris embedded in the tire tread. 11. Since the components were disassembled for maintenance work, a forklift road test must be conducted after reassembly. (1) At different levels of braking performance, there should be no deviation or weaving. On steep slopes, the vehicle can be stopped reliably once the handbrake is pulled tight. (2) Listen to the engine while it is operating under conditions of acceleration, deceleration, heavy load, or no load, to check for any abnormal noises. (3) After driving for a certain distance, check for overheating in the brakes, transmission, front axle housing, and gear pump. (4) Is the lifting speed of the fork frame normal, and is there any shaking? 12. Check whether the fuel inlet filter in the diesel tank is clogged or damaged, and clean or replace the filter. III. Level II technical maintenance: In addition to all the tasks involved in level I technical maintenance, the following operations are also carried out: 1. Clean all oil tanks, filters, and pipelines, and check for any signs of corrosion or damage; after cleaning, do not wipe them with fibers from yarns or fabrics. 2. Clean the torque converter and gearbox, check for wear on the components, and replace the oil with fresh oil. 3. Check the drive shaft bearings, and adjust the direction of the universal joint shaft as necessary. 4. Check the tightness of all components in the drive axle for any oil leaks, and clear the vent holes. Disassemble and inspect the main reducer, differential, and wheel-side reducer; adjust the axial clearance of the bearings, and add or replace the lubricating oil. 5. Disassemble, inspect, adjust, and lubricate the front and rear wheel hubs, as well as swap the half shafts. 6. Clean the brakes and adjust the gap between the brake drum and the brake shoe friction pads. 7. Clean the steering gear and check the free rotation amount of the steering wheel. 8. Disassemble and clean the gear oil pump, paying attention to checking the wear condition of the gears, housing, and bearings. 9. Disassemble the multi-way valve and check the clearance between the valve stem and the valve body; do not remove the safety valve unless necessary. 10. Check the steering knuckle for any damage or cracks, as well as the fit between the steering axle kingpin and the steering knuckle. Inspect the wear on the joints of the longitudinal and transverse tie rods as well as the steering arms. 11. Remove the tire, rust-proof and paint the rim, inspect the inner and outer tires as well as the belts, swap their positions, and inflate them according to the specifications. 12. Check the tightness of the connections of the manual braking components, and adjust the operating travel of the manual brake lever and the foot brake pedal. 13. Check the specific gravity of the battery electrolyte; if it does not meet the requirements, it must be removed for charging. 14. Clean the water tank and oil radiator. 15. Check whether the shelves and frames are deformed, remove and clean the rollers, and verify that all attachments are securely fixed; weld additional parts if necessary to ensure firm fixation. 16. Disassemble and inspect the lifting cylinder, tilting cylinder, and steering cylinder, and replace worn seals. 17. Check all instruments, sensors, fuses, and various switches, and make adjustments if necessary. IV. Lubrication of the entire vehicle: For new forklifts or those that have been out of use for a long time, within the first two weeks of use, it is necessary to lubricate the bearings. When adding oil for lubrication, use fresh oil to push out all the old oil, and apply lubrication more than twice. At the same time, pay attention to the following points: 1. Before lubricating, remove any dirt from the oil caps, plugs, and nozzles to prevent dirt from entering the internal mechanisms. 2. When injecting lubricant using a grease gun, it should be injected until lubricant is forced out from the joints between the various components. 3. Seasonal lubricants (such as engine oil) should be replaced in summer or winter. Precautions for forklift operators: First of all, persons who have not received training and authorization for operating special forklifts must not operate any forklifts; to drive a forklift on roads, at least a Class B driving license is required. To operate a forklift in the work area, a written driving permit issued by the employer is required. Secondly, drivers must never drive under the influence of drugs or alcohol, and they must not smoke or eat while driving – these are basic safety guidelines. The driver must understand the structure and performance of the vehicle, be familiar with the operating methods and maintenance requirements, receive professional training, pass the assessments conducted by the relevant authorities, and be issued a certificate of qualification before being allowed to operate it alone. Driving without a license is strictly prohibited; the driver must be accompanied by a licensed instructor and must not operate the vehicle alone. Furthermore, forklifts must not be modified without the permission of the supplier or manufacturer, in order to prevent damage to their performance. Third, always fasten your seat belt when operating a forklift, as this can protect the driver’s life in the event of an accident and reduce the severity of injuries. Drivers must wear protective shoes when working near forklifts. Adjust the seat, pedals, control levers, and backrest according to personal needs to achieve the optimal driving position. If working in a noisy environment—please use protective earplugs. Furthermore, the driver should stay informed about the technical specifications of the forklift and the loading diagrams to understand what types of goods it can carry and its loading capacity, by referring to the load capacity table. At the same time, changes in the distance of the load center also affect the loading capacity of the forklift; therefore, it is important to pay attention to the explanation of how the distance from the load center influences the load-carrying capacity. Finally, when using forklifts to transport personnel, it is necessary to strictly abide by relevant regulations and learn and comply with the company’s rules. Improper operation can easily lead to accidents. At the same time, it must not carry passengers if there are no designated seats for them. No one is allowed to walk under the lifted forklift to prevent accidents or other incidents in case the cargo tips over. Operational precautions: 1. Only drivers who have received training and hold a driving license may drive ； 2. Check all control and alarm devices before driving; if any damage or defects are found, operate the vehicle only after they have been repaired ； 3. When transporting, the specified load limit must not be exceeded; the forks must be fully inserted under the goods, and the goods should be evenly distributed across the forks. It is not allowed to lift the goods using just the tip of a single fork ； 4. Start, turn, drive, brake, and stop smoothly; reduce speed when turning on wet or smooth roads ； 5. When driving with cargo, lower the load and tilt the mast backward ； 6. When driving on slopes, proceed with caution. On slopes steeper than 10%, drive forward when going uphill and backward when going downhill; do not turn while on an uphill or downhill slope. Do not perform loading or unloading operations while the forklift is in motion ； 7. While driving, be aware of pedestrians, obstacles, and potholed roads, as well as the space above the forklift ； 8. It is not allowed for people to stand on the forks, and the vehicle must not carry passengers ； 9. It is not allowed for anyone to stand under the forks or walk beneath them ； 10. It is prohibited to operate the vehicle and its attachments from any position other than the driver’s seat ； 11. Do not move goods that are not secured or piled loosely; be careful when handling larger-sized goods ； 12. For high-rise forklifts with a lifting height of more than 3 meters, care should be taken to prevent goods above from falling; protective measures must be taken if necessary ； During operation, the boom should be tilted backward as much as possible, with tilting forward and backward being kept to a minimum ； 13. When adding fuel, the driver should not be in the vehicle and the engine must be turned off; do not start the engine when checking the battery or fuel tank level ； 14. When leaving the vehicle, lower the forks to the ground, place the gear lever in neutral, turn off the engine and disconnect the power supply, and engage the handbrake. When parking on a slope, it is also necessary to use blocks to support the wheels. Precautions for forklift loading and unloading operations: Before starting the loading or unloading process, it is necessary to check whether the brakes are functioning properly and to ensure that the forklift is in good working condition – this is the driver’s responsibility. Before each trip, the following areas must be checked: 1 Check the fuel level. 2 Check the oil pipes, water pipes, exhaust pipes, and various accessories for any leaks. 3 Check whether the capacity of the working oil tank meets the specified level. 4 Check the tightness of the wheel bolts and whether the tire pressures are at the specified values. 5 Check the flexibility and reliability of the steering and braking systems. 6 Check whether the electrical wiring is properly grounded, whether the connections are loose, and whether the horn, turn signals, brake lights, and all instruments are functioning properly. Work can only begin after the above preparations are completed. In the event of a fire, the power must be turned off before using a foam fire extinguisher to put out the fire. The distribution room should be fitted with wire mesh to prevent rodent infestations. Care must be taken when moving goods. It is not allowed to handle loads that are unsafe or unstable; proper attention must be paid to the safety and stability of the stacked goods in order to prevent accidents such as tipping over. If the load blocks your view ahead, drive in reverse. Defective or damaged pallets must not be used, as this can lead to accidents. Be sure to place the pallets in designated areas; they must not be placed randomly. When operating a forklift, it is necessary to slow down at turns and sound the horn as a warning to prevent collision accidents. When lifting the pallet, attention should be paid to the lifting height, as it also affects the stability of the forklift. At the same time, it is also important to avoid damage to the forklift caused by heavy loads; during continuous long-term operation, attention should be paid to scheduling rest periods ； If the load capacity is insufficient, be sure to use a larger forklift; do not operate it beyond its capacity. When loading the forklift onto the truck, the driver should pay attention to the total weight of the forklift and ensure that the loading ramp mechanism for loading/unloading the truck functions properly ； The truck tires are locked ； There is sufficient space to accommodate the forklift’s mast; if not, the mast must be separated from the vehicle body before it can be loaded and transported. When loading goods, the distance between the forks should be adjusted according to the size of the goods; the weight of the goods should be evenly distributed between the two forks to prevent uneven loading or the goods from slipping to one side as the forklift moves. As the forks enter the pile of goods, their sides should make contact with one side of the goods; then the frame is tilted backward to lift the forks about 200 millimeters off the ground before moving forward. High-speed sharp turns are strictly prohibited. During driving, it is forbidden to lift or lower cargo, and no one is allowed to be under the lifting frame at any time. When transporting goods on slopes steeper than 7°, the goods should be placed above the slope. When transporting goods, avoid sudden braking and drive at a slow speed to prevent the goods from slipping out. When transporting large-sized goods that block the view, the forklift should drive in reverse at a low speed. It is strictly prohibited to leave the engine idling unattended after parking, and it is even more forbidden to leave the driver’s seat while goods are suspended in the air. When the forklift stops midway with the engine idling, the mast should be retracted by tilting it backward; once the engine is turned off, the slide frame should be lowered and the forks tilted forward so that they touch the ground. During operation, if suspicious noises or abnormal phenomena are detected, the machine must be stopped immediately for inspection, and measures must be taken to resolve the issue; work must not continue until the fault has been fixed. After a day of operation, the fuel tank should be refilled; this not only helps to remove moisture from the tank but also prevents water droplets formed by humid air at night from dissolving into the fuel. Furthermore, no one is allowed to use forklifts without the approval of company management. To extend the service life of the forklift and prevent accidents, as well as to maintain its optimal operating condition and the proper functioning of all its components, it is necessary to carry out regular maintenance on this machine strictly throughout its usage period. This post was last edited by Submarine on 2009-4-13 16:56.]

Our company’s forklifts have been involved in several accidents. The most serious one occurred when handling metal containers of Category B materials; improper handling led to friction between the containers and the ground, which caused the leaked material to catch fire. Fortunately, prompt action was taken, which prevented a larger fire or explosion from occurring.

The forklift driver operated the forklift without a license in violation of regulations, and also carried passengers illegally. While turning, the vehicle overturned, crushing the passengers; they died despite efforts to save them at the hospital.

I am currently preparing a training material on safety for forklift operators, aiming to emphasize the importance of operating procedures by using accident cases as examples. Below are the accident cases I have gathered, most of which come from the HaiChuan forum. 1. An unqualified driver died after the forklift overturned during a sharp turn. Details: The forklift driver failed to remove the keys before leaving the forklift; an unqualified person started the forklift. Due to excessive speed and a sudden change in direction, the forklift overturned, and the death occurred because the driver was not wearing a safety helmet. 2. Death due to falling while working on a lifted pallet: The victim was working on goods placed on a pallet that had been lifted to a height of 2 meters. When attempting to retrieve the goods piled on top, the load supporting the foot slipped, causing the victim to fall and die. 3. A person standing on the counterweight of a forklift fell and suffered serious injuries. Details: Since the load lifted by the forklift exceeded its allowable weight limit, a worker stood on the counterweight at the back of the forklift in an attempt to lift the load. The worker fell and suffered serious injuries due to the forklift tilting forward. 4. Pedestrian in the work area was killed after being struck. Details: A forklift operator loaded goods too high and continued to drive forward with his view obstructed. As a result, it knocked down a pedestrian in the work area and killed them. 5. Death occurred when goods fell due to the use of a forklift that was not properly maintained. Details: The victim entered under the lifted load. The high-pressure oil pipe connecting the forklift’s lifting cylinder and the hydraulic control valve aged and could not withstand the pressure, resulting in a rupture; the load fell and caused death. 6. Died trapped between a forklift moving in reverse and a pallet. Details: A forklift driver was operating a forklift without mirrors or a reverse alarm, and while reversing he crushed to death a person who was counting items in front of the shelf. 7. Died trapped between the door frame and the roof guard. Details: A forklift operator noticed that the load on the forks was tilted, so he got up from his driving seat to straighten it. Since the engine was not turned off, his legs touched the handle for tilting the mast backward, resulting in him being trapped between the mast and the overhead guard and dying as a result. 8. Accident at an intersection: Details: A forklift driver was transporting goods through an intersection, at the same time as a pedestrian was passing through that intersection. The forklift driver applied emergency brakes, but the spilled cargo crushed the pedestrian. 9. No accident was confirmed in the area surrounding the loaded goods. Details: A forklift operator was lifting one of the items in a pile of goods; due to the forks not being in the correct position, other items were pushed aside, resulting in two workers who were discussing work nearby being injured.