1. Safety Training Presentations
FORKLIFT OPERATOR SAFETY TRAINING

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

4. Forklift Safety Hazards
Forklifts are very heavy
Average automobile - 1, ,000 lbs.
Average forklift - 4, ,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

5. 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

6. 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

7. 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. 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. 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. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. Stability Triangle

17. 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

18. 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

19. Tipping Forklift What should you do? Lean in opposite direction
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

20. 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

21. 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

22. 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

23. 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

24. 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

25. 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

26. 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

27. 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

28. 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

29. 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

30. 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

31. 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