1. FORKLIFT OPERATION TRAINING
INSTRUCTOR’S NOTES
FORKLIFT OPERATION TRAINING

2. Why Are We Here? What Can I Teach You About Driving a Forklift?

3. Why Are We Here? What Can I Teach You About Driving a Forklift?
100 deaths per year
95,000 accidents each year

4. Top 10 Forklift Accidents
Pedestrians being struck
Forklift shoves container into an employee
Operator struck by falling load
Operator becoming injured getting on or off
Other employees struck by falling load
Collisions with other vehicles

5. Top 10 Forklift Accidents (cont’d)
Forklift falls off the loading dock
A part of the body hanging outside the forklift when it hits an object
Load falls backward and hits forklift operator
Truck tips over

6. Operator Requirements
Medical requirements
Required training
Written and driving test
Operator’s permit

7. OSHA Requirements TRAINING OF OPERATORS SAFE OPERATION OF FORKLIFT
PROPER MAINTENANCE OF FORKLIFT

8. HOW A FORKLIFT WORKS! PIVOT POINT OR FULCRUM COUNTERBALANCE LOAD
RATED CAPACITY
LOAD CENTER

9. Center of Gravity Balance point
48” A
Distance from the edge of the item to the item’s center of gravity
I. Background for the Trainer:
The center of gravity is an important concept for all forklift operators to understand. Use blocks or Legos® to help demonstrate the location of a load’s center of gravity.
II. Speaker’s Notes:
Before we talk about about capacity and load center, we need to discuss how to determine a load’s center of gravity.
The center of gravity is the exact point on which the entire load will balance. For loads of consistent material, this point will always be near the center of the load.
If a load contains materials with different weights or densities, the load center will be on the side containing the heavy material. For example: If a pallet contains bricks on one side and pillows on the other, the center of gravity will obviously be closer to the side of the pallet containing the bricks.
The distance from the edge of the load to the center of gravity is very important. If possible, the load must always be picked up on the side that is closest to the center of gravity. This will keep the load’s weight closer to the forklift.
The center of gravity of item A above is 24 inches from the edge.
Would it be better to pick up item B from the left or right side? The left side, of course, because the center of gravity is closer to the left side. B
20”
40”

10. Load Center
Distance from carriage of the forks to the load’s center of gravity
A: Load center = 24“ - normal
B: Load center = 40“
Difference =16”
1 inch = 100 pounds
Forklift capacity reduction =1600 pounds
5000 pounds capacity forklift just went to 3400 pounds
Important reason to keep loads as far back on forks as possible!
48”” A
80” B
I. Background for the Trainer:
The concept of load center is a crucial part of understanding the capacity of a forklift. Make sure you, the trainer, understand this concept before trying to explain it in a class.
Most forklifts are rated for a 24-inch load center. The examples used below are based on this assumption. If your forklifts are rated differently, just change the numbers used in the examples.
Once you have explained how the load center affects capacity, use some examples from your facility to drive the point home. For example: If you move around crates that are 60 inches by 80 inches, discuss the load center distances (30" or 40") and how that reduces your lift truck’s capacity.
II. Speaker’s Notes:
The load center is the distance from the carriage, or vertical face of the forks, to the center of gravity of the load. For example, a pallet full of consistent material (e.g., bricks) usually measures about 4 feet by 4 feet. Therefore, the load center will be about 24 inches.
If your forklift is rated for 5,000 pounds at 24 inches, it can safely lift a 5,000-pounds load as long as the center of gravity is 24 inches or less from the front face of the forks.
If the load center is greater than 24 inches, it will reduce the lift truck’s capacity. Each forklift is different; however, it is safe to assume that for every additional inch beyond 24 inches, the capacity will be reduced by 100 pounds
Try to lift a load that is 80 inches long. The load center is 40 inches, or 16 inches greater than the rated load center of 24 inches. If 100 pounds capacity is lost per inch of extra load center, then the capacity of the lift truck is reduced by 1,600 pounds

11. Oh No – MATH! Data Plate Your Load 24” load center 5000 pounds
24 x 5000 = 120,000 inch pounds (forklift moment)
Your Load
36” load center
4000 pounds
Safe to move?
I. Background for the Trainer:
The concept of load center is a crucial part of understanding the capacity of a forklift. Make sure you, the trainer, understand this concept before trying to explain it in a class.
Most forklifts are rated for a 24-inch load center. The examples used below are based on this assumption. If your forklifts are rated differently, just change the numbers used in the examples.
Once you have explained how the load center affects capacity, use some examples from your facility to drive the point home. For example: If you move around crates that are 60 inches by 80 inches, discuss the load center distances (30" or 40") and how that reduces your lift truck’s capacity.
II. Speaker’s Notes:
The load center is the distance from the carriage, or vertical face of the forks, to the center of gravity of the load. For example, a pallet full of consistent material (e.g., bricks) usually measures about 4 feet by 4 feet. Therefore, the load center will be about 24 inches.
If your forklift is rated for 5,000 pounds at 24 inches, it can safely lift a 5,000-pounds load as long as the center of gravity is 24 inches or less from the front face of the forks.
If the load center is greater than 24 inches, it will reduce the lift truck’s capacity. Each forklift is different; however, it is safe to assume that for every additional inch beyond 24 inches, the capacity will be reduced by 100 pounds
Try to lift a load that is 80 inches long. The load center is 40 inches, or 16 inches greater than the rated load center of 24 inches. If 100 pounds capacity is lost per inch of extra load center, then the capacity of the lift truck is reduced by 1,600 pounds

12. NO Is this on the test? Answer
36 x 4000 = 144,000 inch pounds for the load (load moment) to be moved which is more than the 122,000 inch pounds of forklift capacity
I. Background for the Trainer:
The concept of load center is a crucial part of understanding the capacity of a forklift. Make sure you, the trainer, understand this concept before trying to explain it in a class.
Most forklifts are rated for a 24-inch load center. The examples used below are based on this assumption. If your forklifts are rated differently, just change the numbers used in the examples.
Once you have explained how the load center affects capacity, use some examples from your facility to drive the point home. For example: If you move around crates that are 60 inches by 80 inches, discuss the load center distances (30" or 40") and how that reduces your lift truck’s capacity.
II. Speaker’s Notes:
The load center is the distance from the carriage, or vertical face of the forks, to the center of gravity of the load. For example, a pallet full of consistent material (e.g., bricks) usually measures about 4 feet by 4 feet. Therefore, the load center will be about 24 inches.
If your forklift is rated for 5,000 pounds at 24 inches, it can safely lift a 5,000-pounds load as long as the center of gravity is 24 inches or less from the front face of the forks.
If the load center is greater than 24 inches, it will reduce the lift truck’s capacity. Each forklift is different; however, it is safe to assume that for every additional inch beyond 24 inches, the capacity will be reduced by 100 pounds
Try to lift a load that is 80 inches long. The load center is 40 inches, or 16 inches greater than the rated load center of 24 inches. If 100 pounds capacity is lost per inch of extra load center, then the capacity of the lift truck is reduced by 1,600 pounds

13. Stability Triangle Forklift’s center of gravity
3-point suspension
Forklift’s center of gravity
Combined center of gravity
I. Background for the Trainer:
The stability triangle is an effective way to show an operator how their actions can cause a lift truck to tip over so that they know what actions to avoid.
This information on stability is primarily for sit-down counterbalance lift trucks. Other lift trucks, such as stand-up narrow aisle, will probably have different stability concerns.
II. Speaker’s Notes:
A sit-down counterbalance lift truck has a three-point suspension with the weight supported at each front tire and the center of the rear axle. This creates a triangle. As long as the combined center of gravity of the load and the forklift remain within this stability triangle, the forklift will not tip over.
The center of gravity of an unloaded forklift will be just below the operator’s seat.
With a load, the combined center of gravity (black circle) is close to the font edge of the stability triangle.
A near-capacity load with a longer load center (e.g., 30 inches) will create a combined center of gravity that has moved beyond the front edge of the triangle. The forklift will tip forward.
Load center beyond 24"

14. Combined Actions Center of gravity moves side to side
Center of gravity moves forward
I. Background for the Trainer:
This slide is used to show operators how their actions could cause a forklift to tip over. Usually, a tip over does not result from one action but a combination of two or more actions.
II. Speaker’s Notes:
What causes the center of gravity of a lift truck to move from side to side?
Forklift cornering, unbalanced load, tire going into a pothole, sloped surface
What causes the center of gravity of a lift truck to move forward?
Capacity load, mast tilted forward, stopping abruptly when going forward, quickly accelerating in reverse, driving down a ramp
What causes the center of gravity of a lift truck to move backward to the thin portion of the stability triangle?
Mast tilted back, stopping abruptly when going in reverse, quickly accelerating forward, driving up a ramp
Which of the above actions, when combined, could cause a forklift to tip over? A forklift cornering while driving up a ramp would cause the center of gravity to be back and to the side, thus resulting in a tipover. A forklift moving forward with a raised capacity load could tip forward if forced to stop abruptly. A forklift cornering with an unbalanced load and then hitting a pothole could easily tip over. These are just a few examples of how a forklift can be tipped over.
Center of gravity moves backward to the thin portion of the triangle

15. GENERAL SAFETY GUIDELINES
ONLY TRAINED EMPLOYEES CAN OPERATE A FORKLIFT
INSPECT BEFORE OPERATING
MAXIMUM SPEED - NORMAL WALKING SPEED
OPERATE ONLY FROM OPERATOR POSITION
WEAR SEAT BELTS!
SOUND HORN AT BLIND INTERSECTIONS
LEAVE ROOM BETWEEN MOVING FORKLIFTS
KNOW LIMITATIONS/LOAD CAPACITY
NO RIDERS!!!

16. Attachments Only attachments approved by forklift manufacturer
New data plate required due to changes in forklift capacity and center of gravity
No modifications made to the forklift without manufacturer approval

17. INCLINES TRAVEL WITH LOADS FACING UPHILL. CHECK FOR TRACTION
FORWARD - GOING UP
BACKWARD - GOING DOWN
CHECK FOR TRACTION
CHECK FOR STABILITY
IF DOCK BOARDS, CHECK FOR WHEEL CHOCKS ON TRAILER

18. PARKING NEVER PARK IN AISLE , IN FRONT OF EXIT OR EMERGENCY EQUIPMENT.
LOWER FORKS TO THE FLOOR.
SHUT TRUCK OFF, REMOVE KEY
SET BRAKE, IF APPLICABLE.
VERIFY SAFETY SWITCH ON SEAT.
STEP DOWN FROM TRUCK, DON’T JUMP!

19. DRIVING IN REVERSE
Sound horns when approaching aisleways and doorways.
When obstructs view
Going down ramps with load
Constantly looking over shoulder

20. Tipping Over Do not jump Hold onto the steering wheel Brace your feet
Lean away from the fall
I. Background for the Trainer:
If the forklift operators drive safely and consider the combined actions that might cause them to tip over, they should never tip over in the first place. But, if there is a tipover, it is important that they know what to do.
II. Speaker’s Notes:
Do not jump. You should be wearing the seat belt so that it would be hard to jump if you had the seat belt secured. Many operators who thought they could jump clear of a tipover have been crushed by the overhead guard or the mast of the forklift.
Seat belts must always be worn. Many fatalities have occurred when an unseatbelted operator was thrown clear of the forklift and struck his or her head on a solid object.
Brace yourself by holding firmly to the steering wheel and planting your feet.
Lean away from the fall.

21. Stopping Distance Traveling at 8 mph (12 ft/sec)
.75 sec. Perception time (9ft.)
+ .75 sec. Reaction time (9ft.)
= 1.5 sec. Lost Stopping Time (18ft.)
Truck traveled 18 feet before the brakes were even applied

22. DAILY INSPECTION REQUIRED BEFORE OPERATION REQUIRED EVERY SHIFT
TURNED IN AT END OF WEEK

23. Common Violations

30. Resources Inspection form Drivers License Sample Test Performance Test
Certification