1. Power Industrial Truck Training
Each year many forklift accidents occur in the workplace causing personal injuries, vehicle damage and lost production time. Many of these accidents can be prevented by using proper safety techniques and common sense. You, as a forklift operator, need to understand specific safety precautions in order to protect yourself and your co-workers.
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2. Lift Truck Training Designed to: Communicate safe operating procedures
Discuss lift truck types & inspection procedures
Evaluate competency to operate a lift truck
Lift trucks or forklifts training is designed to accomplish a number of things. Since tremendous damage to people and property can occur, it is important that safe operating procedures are communicated. Communication of these procedures will give all employees, not just the fork truck operator, a safer work environment.
Another reason is to discuss the types of forklifts, and the importance of conducting an inspection of each forklift before you start your shift.
Lastly, it is to evaluate your competency to operate a forklift. This will include classroom & operational training. Operational training will be based on previous knowledge and skills, type or types of trucks you will operate, hazards you may encounter in these operations and how well you demonstrate your ability to operate a power industrial truck.
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3. The Powered Industrial Truck
A powered industrial truck is defined as a mobile, power-driven vehicle used to carry, push, pull, lift, stack, or tier material.
Vehicles NOT covered by the Powered Industrial Truck standard are compressed air or nonflammable compressed gas-operated industrial trucks, farm vehicles, and vehicles intended primarily for earth moving or over-the-road hauling.

4. Lift Truck Components Forks Backrest Mast Heel Lift & Tilt Cylinders
Overhead Guard
Mast
Forks
Half-tapered
full-tapered
Backrest
Mast
Heel
Lift & Tilt Cylinders
Overhead Guard
Carriage
Backrest
Forks
It is important to understand the components that make up a forklift. The 6 major ones are:
The Forks, which are used to lift the load and come in two types:
Half tapered forked generally increase in thickness from the tip of the fork to about midway back where the blade reached its maximum thickness. These half tapered forks are generally used for heavier loads.
Full tapered forks gradually increase in thickness from the tip of the fork all the way back to the fork’s heel. Full tapered forks are generally used for lighter loads.
The backrest, which supports the load when tipped back and adds stability.
The mast, which is a set of track housing ball bearings rollers and chains. This mechanism raises and lowers the load. The mast will have more than one lifting section.
The heel, which is the connection of the forks and the backrest.
Lift and tilt cylinders, which are hydraulically operated devices. The tilt cylinder works in both forward and a backward direction, while the lift cylinder works in only one direction.
And the overhead guard, which protects the operator from falling debris. It is importance to remember that an overhead guard is designed to deflect a falling object or withstand its full impact.
Heels
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5. Different Types of Powered Industrial Truck
High-lift rider - allows for materials to be stacked and tiered.
Stockpickers - allows for gathering and carrying materials at high evaluations
Walkies - moves and sometimes stacks materials while the operator walks along with the unit

6. Types, Features & Physics
Basic Designs
Counterbalanced - has the weight at the rear of the truck
Pivot Point
Straddle - Weight is supported by outriggers that straddle the load
The basic concept of a PIT is it’s design. The two basic designs are Counterbalance & Straddle. It should be noted that all PIT’s designs are based on the location of the pivot point.
A Counterbalance design has more weight at the rear of the truck to counter the weight of the load --- much like a teeter totter. This pivot point is at the center of the load wheels. On electric trucks, the battery is a major component of the counter-weight. that’s why it’s important to know the minimum battery weight.
A Straddle design is supported by outriggers in front of the truck which straddle the load. the pivot point is extended into the load area. Straddle trucks can weight less and be shorter in length because less counterbalance advantage is needed.
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Pivot Point

7. Types, Features & Physics
Free Lift - the height you can lift the forks before the overall collapsed height of the truck is increased.
Collapsed Height - distance from the floor to the highest point on the truck.
Maximum Fork Height - The maximum height that your truck can lift a load
Free Lift
Collapsed Height
There are several truck measurements you should be familiar with :
Free Lift is the height you can lift the forks before the overall collapsed height of the truck increases. Free lift is very important if you’re lifting and moving materials within confined spaces, such as trailers or boxcars. Make sure you know how high your forks will lift before the overall height of the truck starts to increase.
Collapsed Height is the distance from the floor to the highest point of the truck when the mast is fully lowered. Knowing the collapsed height is important when passing through doorways, under racks or into trailers and boxcars.
Maximum Fork Height is the maximum height that your truck can lift a load. It is measured from the floor to the top of the forks. You may have different lift heights in different areas of the warehouse.
Overall Extended Height is the distance from the floor to the top most part of the truck when the mast when the forks are fully raised. Overall extended height is important to know in order to avoid sprinklers and overhead obstructions.
Maximum Fork Height
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8. Types, Features & Physics
Teeter-Totter
Fulcrum Point - a center pivot point of a lift truck
Center of Gravity - a balance point directly over the center pivot point
Leverage - When the center of gravity shifts because of added weight. CG
In order to safely operate PIT’s it’s important to understand how the trucks are designed to safely move and lift a load. When we were growing up we played on a teeter-totter --- a simple machine. When handling loads, your forklift is basically a large lever much like that teeter-totter. The point at which a lever pivots is known as the fulcrum point. On a forklift the fulcrum point is usually the front wheels.
We know that equal weights which are an equal distance from a center pivot point or fulcrum will balance. That balance point, located directly over the fulcrum is the “Center of Gravity”.
When weight is added to one side or just moving the weight on one side farther from the pivot point will create an imbalance. The center of gravity is shifted to the side with the weight or leverage advantage. CG
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9. Types, Features & Physics
Fulcrum

10. Types, Features & Physics
Stability Triangle
An imaginary area between the wheels closest to the load and the center point of the rear axle.
Lift trucks have a 3-point suspension
the center of gravity is a point within the stability triangle
Load Center
on evenly distributed loads the load center is one-half the length of the load.
The Stability Triangle is an imaginary area between the truck’s pivot point - usually the wheels closest to the load - and the center point of the truck rear axle. Most lift trucks, even those with four wheels have a 3-point suspension. this is because the rear axle is connected to the truck be a center pivot point. PIT’s can operate safely when the center of gravity remains within this triangle.
A Load Center of gravity depends upon its stability. The load center of gravity is usually measured in terms of distance from the back or front of the forks, and the height of the load. Generally speaking the the load center is one-half the length of the load. Also, the lower the load the better the stability.
Remember the weight of your load is counterbalanced by a counterweight at the rear of the lift. Simply stated, you must always be sure that the weight on forklift side is greater that the weight on the load side. Too much weight on the load side will cause loss of steering and can cause the forklift to tip.
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11. Types, Features & Physics
When the load is lifted, the Stability of the load changes.
An uneven load will cause the load to escape the stability triangle sooner.
If your loads are unstable or not balanced properly, this can cause the load to escape the stability triangle sooner. Once a load shifts or starts to shift the center of the load will move outside the stability triangle. If the load where to shift on an sloped sloped surface the chance of the PIT tipping is even greater.
Lifting a load will also change the stability triangle. The higher the load is lifted the smaller the stability triangle becomes. It is important to know the height and load limits of the PIT you are operating.
Stability Triangle

12. ID Plate Rated load (weight) capacity Fork Height Various Load Center
NOTE: It is your responsibility to know how much a load weights.
An ID or capacity plate usually indicates a load or weight limit, the maximum fork height when lifting a load and the maximum position of the load center of gravity.
It might also list what special attachments can be added to the forklift, but when these attachments are add the load or weight limit listed on the ID plate will become smaller.
It is your responsibility to know the load limit of the forklift you are driving.
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13. Lift Truck Vs Automobiles
Smaller wheel base
Shorter turning radius
Steers from the rear
No Springs or Shocks
Weights ~ 15,000 pounds
Automobiles
Larger wheel base
Large turning radius
Steers from the front
Full Suspension System
Weights ~ 3,000 pounds
In many ways a forklift is much like an automobile. It has four wheels, a steering wheel and operates on the same principles. The big difference is that it does not handle the same.
A smaller wheel base and shorter turning radius allow for the forklift to tip-over easier at a lower speed.
Forklifts also steer from the rear which means that the rear of the lift requires much more room to make a turn.
No springs or shocks allows for a rougher ride with a danger of be thrown from the lift at excessive speeds.
A forklift can weight almost 5 time as much as car.
Other major differences are that a forklift has limited visibility when carrying a load, different center of gravity and different controls.
One thing a forklift and car have in common is that you need to wear your seat belt at all times when operating either..
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14. Driving Your Truck Vision Obstructions Braking Rules of the Road
Environmental
Load
Vehicle design
Personal
Braking
Plugging
Rules of the Road
Follow local traffic rules
Pedestrian rights
Vision obstructions are common occurrences when operating a forklift and there are is several different types: environmental, load obstructions, vehicle design and personal obstruction.
Whenever there is an environmental or work place obstruction, slow down, sound your horn and slowly move past the obstruction. Be prepared to stop immediately. This is especially important at cross aisle and other points where vehicle collisions are possible.
If the load is causing the obstruction, drive your vehicle backwards with the load trailing. Take extra caution when driving backward, since the steering wheels are now at the front of the vehicle, changing the characteristics of your forklift.
If the vehicle design causes a vision obstruction, get into the habit of looking around the obstruction. You may even want to place some type of sticker or marking on the obstructions to remind you of its presence. Remember a forklift can have blind spots just like a car.
If you encounter personal vision obstructions (something that blocks your vision), stop the vehicle and correct the problem immediately. Never drive your forklift while dealing with personal vision obstruction.
All PIT’s have a braking system to stop truck’s movement. These systems can be very different based on the specific type of truck, so get the feel of the brakes of the truck you will be operating. Many trucks allow you to slow down or stop by a method called “plugging”. Plugging is when an operator shifts the direction control into the opposite direction of travel and uses the drive unit to gradually slow the movement of the truck. Thought plugging is a safe way to stop a truck, it will not stop a truck as quickly as braking. Always use the brakes in congested areas, on ramps or when a quick stop is necessary. On most PIT’s plugging is not possible when the brakes are applied.
Rules of the road are fairly simple --- follow local traffic rules and give pedestrians the right of way.
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15. Driving Your Truck Driving Conditions Ramps / sloped surfaces
Closed Environments
Unique Hazards
Vehicle Restrictions
Aisle Space
Not all driving surfaces are smooth, level concrete floors. Special care must be taken driving on ramps or sloped surfaces. Always ascend or descend grades slowly. Always drive with the load upgrade. If the load must be downgrade for any reason, make sure the load engaging mechanism is tilted up and raised only as far necessary to clear the road surface. Also when descending a grade with a load, put the truck in low gear if one is available.
When driving into a closed environment, such as a trailer always make sure that the trailer is chocked. Always cross over dock plates slowly and squarely.
Be aware of hazards that are unique to the work area and understand your vehicle restrictions, which can be found in the manufacturer’s operating manual.
When turning into aisles, make sure there is enough room for the rear of the vehicle. When approaching intersections, look both ways and ahead for traffic. Use your horn to signals others of your presence. Also, be aware of pedestrians walking or working in the aisles --- remember that pedestrians have the right of way, so prepare to give it to them.
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16. Daily Inspection Items:
Horn: Does it emit an audible sound?
Steering: Does the steering feel firm, allowing for good control?
Lights: Required for entering trailers.
Hydraulic Controls: Any noticeable leaks or wear points?
Brakes: Are they in good working order?
Power source: Is battery or tank in good condition?
Tires: Are tires free of excess wear, is rubber separated from rim?
Forks: Are forks equally spaced & free from cracks?
Seat Belt: Is the seat belt operational or in working condition?
Any defects, take the truck OUT of service.
Before operating a PIT, it must be inspected each shift to make sure that the PIT is in safe operating condition. A PIT and its operational conditions can change from day to day, from shift to shift and from load to load. That’s why it is important to perform a thorough inspection at the start of your shift.
The following should be inspected and logged each shift.
Horn: Does it emit an audible sound?
Steering: Does the steering feel firm, allowing for good control?
Lights: Required for entering trailers.
Hydraulic Controls: Any noticeable leaks or wear points?
Brakes: Are they in good working order?
Power source: Is battery or tank in good condition?
Tires: Are tires free of excess wear, is rubber separated from rim?
Forks: Are forks equally spaced & free from cracks?
Seat Belt: Is the seat belt operational or in working condition?
Any defects, take the truck OUT of service.
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17. Load Handling Picking up a Load
Make sure no one is standing near the load.
Approach the load straight on.
Stop with fork tips about 1 foot from load.
Level the forks, then slowly drive forward until the load is resting against the mast.
Tilt the mast back slightly to stabilized the load.
Back the load out.
Lower or raise the load to travel height.
Picking up a load is more than just pulling up to a skid and lifting. There are specific steps that will help ensure that loads are lifted safety --avoiding damage to the load, forklift and other property, as well as avoiding injury to yourself or your co-workers.
Pick up a load using the following steps:
Make sure no one is standing near the load.
Approach the load straight on.
Stop with fork tips about 1 foot from load.
Level the forks, then slowly drive forward until the load is resting against the mast.
Tilt the mast back slightly to stabilized the load.
Back the load out.
Lower or raise the load to travel height.
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18. Load Handling Putting Down a Load
Square up to the location, then stop about 1 foot away
Level the forks and then drive the rest of the way in.
Lower or raise the load.
Tilt forks slightly forward to avoid hooking load while backing out.
Back straight out until forks have cleared.
Like picking up a load, safely putting down a load also requires some specific steps.
Square up to the location, then stop about 1 foot away.
Level the forks and then drive the rest of the way in.
Lower or raise the load.
Tilt forks slightly forward to avoid hooking load while backing out.
Back straight out until forks have cleared.
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19. Load Handling Stacking a Load
Make sure the materials in the stack will not be crushed. Square up to location and stop about 1 foot away.
Lift the mast to stacking location.
Inch forward, level forks.
Square load, then lower to stacking location.
Tilt forks slightly forward and back straight out until forks have cleared.
Stop 1 foot away and lower forks to travel position.
Materials may need to be stacked in order to save floor space. In these situations you may have to use your forklift to stack and un-stack materials. The same safety rules used for picking up and putting down loads will apply, but with some additional safety factors.
This is because the higher you lift your load, the more unstable the forklift becomes.
Stacking rules are:
Make sure the materials in the stack will not be crushed. Square up to location and stop about 1 foot away.
Lift the mast to stacking location.
Inch forward, level forks.
Square load, then lower to stacking location.
Tilt forks slightly forward and back straight out until forks have cleared.
Stop 1 foot away and lower forks to travel position.
Always stack the load square and straight
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20. Load Handling Un-stacking Square up to load and approach straight on.
Stop with forks about 1 foot from stack.
Raise the mast to the load height.
Level the forks, then drive slowly forward until load is resting against the mast.
Lift the load high enough to clear whatever is under it.
Back out about a foot, then lower mast to traveling position
Tilt fork back
Un-stacking rules are:
Square up to load and approach straight on.
Stop with forks about 1 foot from stack.
Raise the mast to the load height.
Level the forks, then drive slowly forward until load is resting against the mast.
Lift the load high enough to clear whatever is under it.
Back out about a foot, then lower mast to traveling position.
Tilt fork back.
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21. Load Handling Traveling with a Load
Never raise the load while traveling.
Keep the load tilted slightly back.
Keep forks as low as possible.
Never speed or perform dangerous maneuvers.
Drive backwards if you can’t see over the load.
Consider the front wheel as the point that the entire lift truck pivots around because turning causes the back to swing wide.
Always slow down to turn.
Stay wide when turning into an aisle.
Once a load has been safety picked up, you need to keep some safety factors in mind when traveling with the load. Safe traveling helps avoid injuries and property damage throughout the workplace.
Keep the following in mind when traveling with a load.
Never raise the load while traveling.
Always keep the load tilted slightly back.
Keep forks as low as possible.
Never speed or perform dangerous maneuvers.
Drive backwards if you can’t see over the load.
Consider the front wheel as the point that the entire lift truck pivots around because turning causes the back to swing wide.
Always slow down to turn.
Stay wide when turning into an aisle.
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22. Load Handling Traveling with a Load - cont...
Never turn wide on a decline.
Never exceed the rated capacity.
Don’t lift a load if you doubt that your lift truck can.
Make sure the load is stable and will not shift.
Have the load face up a decline never down.
Apply even pressure to brakes to stop gradually.
Observe all traffic rules & signs.
Slow down when approaching aisles, ramps, uneven or slippery surfaces.
Always maintain a safe distance (3 truck lengths) when following other lift trucks.
Traveling with a Load - cont...
Never turn wide on a decline.
Never exceed the rated capacity.
Don’t lift a load if you doubt that your lift truck can.
Make sure the load is stable and will not shift.
Have the load face up a decline never down.
Apply even pressure to brakes to stop gradually.
Observe all traffic rules & signs.
Slow down when approaching aisles, ramps, uneven or slippery surfaces.
Always maintain a safe distance (3 truck lengths) when following other lift trucks.
If the load is high obstructing forward view, it is usually recommended to drive in reverse.
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23. Lifting People
A work platform equipped with a standard railing firmly secured to the carriage or forks must be used
Falling object protection must be provided if a hazard exists
An operator must attend the forklift while workers are on the platform
The operator must be in the normal operating position while raising/lowering the platform
A guard must be provided between the worker(s) and the mast if exposure to the chains and/or shear points exist
Maintain stability of the truck and ensure the load capacity is not exceeded (account for platform, workers, materials, etc.)

24. Lifting People Top Rail = approx. 42” Mid Rail = approx. 21”
Make sure the platform is secured to the forklift’s carriage!
A new load center for longer/wider platforms reducing the nominal capacity.

25. Operator Responsibilities
Know the safe operating procedures related to routine forklift operations.
Understand all the critical parts or components of the lift truck.
Complete the inspection checklist before each shift.
Follow all safety rules in the workplace.
Report all injuries and property damages immediately.
Never operate a lift truck under the influence of alcohol, drugs or prescribed medications that may impair alertness.
Know the capacity of the lift truck & the weight of the load to be lifted. Never exceed the rated capacity of the lift truck.
Be alert and look for conditions that might not be safe for the type of lift truck being operated.
Operating a forklift safely requires you to understand how the forklift works, what it can and cannot do, how to safely pick up and put down loads, how to stack and un-stack loads and how to travel with a load.
As a forklift operator your are responsible for the operating a forklift safely. This includes the following:
Knowing the safe operating procedures related to routine forklift operations.
Understanding all the critical parts or components of the lift truck.
Completing the inspection checklist before each shift.
Following all safety rules in the workplace.
Reporting all injuries and property damages immediately.
Never operate a lift truck under the influence of alcohol, drugs or prescribed medications that may impair alertness.
Knowing the capacity of the lift truck & the weight of the load to be lifted. Never exceed the rated capacity of the lift truck.
Being alert and look for conditions that might not be safe for the type of lift truck being operated.
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26. Safety Concerns Remember, safety is everyone responsibility!!!!
No riders allowed
Wear seat belt at all times.
Drive at safe speeds & maintain control of the truck at all times.
Watch for pedestrians & the operator will give the right-of-way to pedestrians.
Never bypass or remove any safety device.
Maintain at least 3 truck lengths from a truck ahead.
Slow down & sound your horn at intersections & other areas where vision is obstructed.
Drive backwards when carrying a load that obstructs your forward view.
Slowly ascend or descend any grades.
Keep forks as close to the ground as possible.
No stunt driving or horseplay.
Please follow these basic operating tips when you are driving your forklift!!!
No stunt driving or horseplay.
No riders allowed.
Wear seat belt at all times.
Drive at safe speeds & maintain control of the truck at all times.
Watch for pedestrians & give the right-of-way to pedestrians.
Take turns at safe speeds.
Maintain at least 3 truck lengths from a truck ahead.
Slow down & sound your horn at intersections & other areas where vision is obstructed.
Drive backwards when carrying a load that obstructs your forward view.
Slowly ascend or descend any grades.
Keep forks as close to the ground as possible.
Being successful at your job probably will depend mainly on your ability to work safely and efficiently. Use this ability to create a safe work environment.
Remember, safety is everyone’s responsibility!!!!
Remember, safety is everyone responsibility!!!!
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27. QUESTIONS