Forklift operators must receive safety training to understand the hazards of operating forklifts. Forklifts can weigh several tons and tip over easily if not operated properly. The training covers pre-use inspections, driving safely with loads, stacking and unstacking loads, and yielding to pedestrians. Proper handling of propane tanks and batteries is also reviewed to avoid fire hazards. Overall, the training emphasizes understanding forklift stability and preventing accidents that can cause injuries.

1. Safety Training Presentations
FORKLIFT OPERATOR SAFETY TRAINING

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3. 3
Forklift Operator Training
• Who needs forklift training?
– Anyone who operates a forklift
• Who must conduct the training?
– A knowledgeable trainer
• Why is training necessary?
– Forklifts pose many hazards
• Approx. 100 deaths and 38,000 injuries/year
• Most Common accidents:
– Tip over
– Struck by lift or struck by load

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Forklift Safety Hazards
• Forklifts are very heavy
– Average automobile - 1,000 - 2,000 lbs.
– Average forklift - 4,000 - 8,000 lbs.
• Loads can be heavy
– Too heavy to lift by hand
• Forklifts or their loads can be unstable
– Forklifts can roll over easily
– Loads can fall off forks or cause roll over

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Pre-Use Inspections
• Inspect forklift before each use
– Don’t know condition left in by last user
– Not inspecting the forklift prior to use could
lead to a hazardous situation or cause serious
damage to the forklift and/or the load

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Pre-Use Checklist
• Brakes
• Steering
• Horn
• Lights
• Oil
• Coolant
• Battery/LP Tank
• Hoist
• Forks
• Engine/Drive Motor
• Tires
• Misc.
– Cage
– Seat belt
– General overall
condition of the forklift

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Pre-Use Inspection - Lift Mechanisms
• Inspect mast for damage
– Broken or cracked weld point
• Make sure roller tracks are greased and free
to travel
• Inspect forks
– Cracks on ends, along blades or at heels
– Make sure not bent
• Check hydraulic lines and fluid levels

8. 8
Pre-Use Inspection - Lift Mechanisms
• Inspect all lift and tilt cylinders
– Leaks
– Mounting hardware
• Inspect tires
– Excessive wear
– Proper inflation (if not solid rubber)

9. 9
Propane Tank Inspection
• Inspect cylinder for damage
• Cracks and broken weld points
• Inspect
• Valves, nozzles and hoses
• Be aware of flammability
• Three ways to detect leaks
• listen for gas escaping
• smell odor
• look for frost on the coupling

10. 10
Changing Propane Tanks
• No smoking!
• Shut off cylinder valve before turning off
forklift to reduce pressure in the fuel line
– Liquid propane is approx. -40 degrees
• Wear heavy duty rubber gloves
• Wear safety glasses
• Make sure pressure relief valve points
straight up when replacing the tank

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Battery Charging
• Inspect batteries for worn parts and cables
• Beware of acid
– No smoking
– Wear faceshield, goggles, apron, rubber gloves
– Only add water after charging
• Make sure charger is off before disconnecting the
battery
• Remove all jewelry
• Use hoist or roller system when replacing

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Capacity Plates
• Must be on all forklifts
– If missing or illegible, replace
• Information found on capacity plates
– Model #
– Max load weight
– Max lift height
– Serial #
– Manufacturer information

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Starting the Forklift
• Apply the foot brake
• Shift gears to neutral
• Turn the key
• Check gauges and indicators
• Check controls, steering and brakes for
smooth operation

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Operating the Forklift
• Know locations and functions of all controls and
gauges
• Be aware of what is going on around you
• Be aware of potential problems with the forklift
• Be sure path of travel is free from hazards
• Traveling speed in doors should not be any faster
than a quick walking pace

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Handling and Moving Loads
• Check the Capacity Plate to be sure the forklift
can handle the load
• Check the load for weight and stability
– If load is not marked
• Contact distributor/shipper of the load
• Lift the load 1-2 inches to test the stability of the rear wheels
and the forklift
• If the forklift struggles, set the load down and if possible break
load into smaller, more manageable loads

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Stability Triangle

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Stability Triangle
• The closer the center of gravity (CG) is to line BC the
more stable the forklift is
• The closer the CG is to lines AB or AC the more unstable
the forklift becomes
• If the CG ever goes outside the stability triangle, the
forklift can tip
– Loads too heavy or offset
– Taking corner too fast
– Traveling surface is not level

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Fulcrum Point
• The front wheels of the forklift are the fulcrum point
– The rear of the forklift has counter weights to help off set the
weight of the load
• Unloaded forklift is unstable - all the weight is in the rear
– When the forks are loaded the weight of the forklift and load are
more evenly balanced
• Loaded forklift is more stable
– When the load out weighs the counter weight the forklift can tip
forward when the load is raised

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Tipping Forklift
• What should you do?
– Must be wearing seatbelt
• Will keep you from falling out of caged area
– Hold tightly to steering wheel with both hands
• Keep hands and arms inside caged area
– Plant feet flat on floor and press down
• Keeps body stable and keeps legs in caged area
– Lean in opposite direction

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Handling and Moving Loads
• Picking up load
– Approach the load straight on with the forks in
the travel position
– Stop when the fork tips are approx. 1 foot away
from the load
– Level forks and drive slowly forward until load is
against backrest
– Lift the load high enough to clear what is under it

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Handling and Moving Loads
• Picking up load (cont.)
– Look over both shoulders to make sure you are
clear and slowly back out one foot
• Sound horn before backing if can’t clearly see
behind you
– Slowly tilt mast back to stabilize the load

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Handling and Moving Loads
• Setting down the load
– Drive to location, square up to load area and
stop about one foot away
– Level the forks and slowly drive forward
– Lower the load
– Tilt the forks slightly forward
– Look over your shoulders and back straight
out until the forks clear the load

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Stacking and Unstacking
• Lifting a load
– Approach the load slowly with the forks in the
travel position
– Stop approx. one foot away from the load and
raise forks to correct height
– Level forks and drive forward until load is flush
against backrest

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Stacking and Unstacking
• Lifting a load (Cont.)
– Lift high enough to clear the bottom load, look
over both shoulders to see if clear to back and
slowly back straight out
– After clearing top of stack, stop and lower mast
to travel position
– Tilt forks back
– Proceed to destination

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Stacking and Unstacking
• Stacking a load
– Approach placement area slowly and square
– Stop about one foot away and lift mast high enough
to clear the placement area
– Move forward slowly until the load is square over
the stack
– Level the forks and lower the mast until the load is
resting on the stack
– Slowly back straight out

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Stacking and Unstacking
• Additional tips
– Never lift a load while moving
– Stop completely before raising the mast
– Make sure the top load is squarely stacked on
bottom load
– Always approach and leave the load area
slowly
– Always look over shoulders before backing up

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Driving with a Load
• Travel with load tilted slightly back for stability
• Travel with the load at the proper height
• 4-6 Inches at fork tips
• 2 Inches at heels
• Drive in control
• Drive in reverse if you cannot see over the load

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Driving on Inclines -
Ramp/Slope• Always drive with the heavier or less stable end of
the forklift pointing up the incline
– If the forklift is loaded (heavier/less stable in front)
• Drive forward up the incline with the load
• Drive in reverse coming down the incline with the
load pointed up the incline
– If the forklift is not loaded (heavier in rear)
• Drive forward down the ramp
• Drive in reverse going up the ramp

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Stopped Forklift
• When Parked or unattended
– Forks flat on ground
– Turn off engine
– Set parking brake
– Do not block:
• Exits
• Emergency equipment
• Signs or postings

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Pedestrians
• Pedestrians have the right of way
– Slow down at intersections
– Look before backing
– Use horn when coming around blind corners and at
blind intersections
– Check mirrors at intersections if they are present in
workplace
• Pedestrians must be cautious in areas where
forklifts may be operating

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Conclusion
• Forklifts are more hazardous than most people
usually perceive them to be
• Pre-use inspections must be performed before
each shift
• It is important to understand how the load will
affect the stability of the forklift
• The operator must always be on the look out for
hazards and pedestrians