Forward

Safe and efficient operation of a lift truck requires skill

and alertness on the part of the operator. It is the
responsibility of the employer to make sure that the
operator can see, hear, and has the physical and mental
ability to operate the equipment safely. (Hyster Company)

Table of Contents
1. Power Point Presentation
Will include a review of:
• General requirements
• Truck related topics
• Work related topics
• Operator evaluation
• Pedestrian awareness
2. Handout exercise for page 15
3. Sample daily checklist for page 16
4. Handout exercise page 26
5. Sample evaluation forms
6. Lift Truck Training Test answer sheet
7. Certificate

“Funding and support for this project has been

provided by the State of Washington, Department
of Labor & Industries, Safety & Health Investment
Projects.”

Building Strong Leaders Since 1960 1

 Forklift Training for Operators

Start your class with an opener that gets their attention.

Example:
Why should we care if operators are trained?
Question:
Has anyone in the group been involved or witnessed a forklift accident? Ask if
they would like to share with the group? Share a story you know about with
your class. Could any of these happen to us?

Let the class know there will be a test at the end of the presentation. Each
person will have to receive 80% correct before passing this training course.

2
 Why Forklift Operators Should be Trained

– Approximately 85 forklift
fatalities and 34,900 serious
injuries occur every year in
the United States
– Fatal Accident Types
• 42% Forklift overturn
• 25% Crushed between vehicle
and a surface
• 11% Crushed between two
vehicles
• 10% Struck or run over by a
forklift
• 8% Struck by falling material
• 4% Fall from platform on the
forks

Discuss main causes of forklift fatalities. Could it happen to anyone of us?

Course Overview

• Types of Forklifts
• General Requirements
• Truck Related Topics
• Work Related Topics
• Operator Evaluation
• Pedestrian Awareness

We will cover each of these areas.

3
 Types of Forklifts

Seven Classes of Forklifts

– Class I - Electric motor rider trucks

– Class II - Electric motor narrow aisle trucks
– Class III - Electric motor hand trucks or hand/rider trucks
– Class IV - Internal combustion engine trucks (solid/cushion tires)
– Class V - Internal combustion engine trucks (pneumatic tires)
– Class VI - Electric and internal combustion engine tractors
– Class VII - Rough terrain forklift trucks

Each trainer may customize this page to fit the type of forklifts they use at their
location.

Example:
If your location has Propane powered forklifts with pneumatic tires it would be a
Class V. You could highlight Class V to bring their attention to it.
Class V - Internal combustion engine trucks (pneumatic tires)
You could also add pictures of forklifts at your location.

Once you have identified the class of forklift in your facility, ask the group what
hazards are associated with the operation of that particular type of forklift.

Be sure that the typical hazards associated with your workplace are covered.

4
General Requirements

Regulations

– Forklift operator must be at least 18 years old

– Overhead guards, view above can not be
blocked
– No modification that affects capacity without
manufacturer’s approval
– Capacity data plate
– Seat belts
– No Passengers

You have to be 18 years old to work in an industrial environment and this

includes operating equipment like a forklift. We will look at each of the following
items in the next few slides.

If any of these do not apply at your workplace, tell your group they don’t apply
to our workplace.

5
 Overhead Guard — View Can Not Be Blocked

What is wrong with this picture?

Operators must have an unobstructed view for stacking or lifting overhead. Clear covers
are available from manufactures. Mention any other behaviors/things you’ve seen
operators do that could obstruct their view.
If this doesn’t apply skip this slide.

No Modifications That Affect Capacity

What’s wrong with this picture?

Ask the class if they have seen any modifications like this?
Any modifications should be reported to a supervisor.
Modifications can not be made without written approval from the manufacturer.

6
 Forklift Data Plate

– Regulations require a legible

nameplate
– Includes information about
the forklift and attachments
– Describes:
Capacity and Load Center

Data Plates contain:

• Capacity information, including load center information.
• 24 inch load center is the industry standard.
• Type of forklift
• Attachment information
• Model and serial numbers
The data plate must be legible; if it can not be read, report it on your daily inspection
and/or tell a supervisor.
New data plates can be ordered from the manufacturer.

7
 Seat Belt or Fall Protection

What is the company policy on seat belts, what will happen if an operator is not wearing
his or her seat belt?

Seat belts are required. If your forklift does not have a seat belt, contact the
manufacturer for a new seat with seat belt attached.

When fall protection is used there will have to be separate training on the use and care
of fall protection.

No Passengers

• Only the operator can ride

on the forklift
• Unless the forklift is
designed for passengers,
do not give anyone a ride

Ask the class if they have seen any one riding on a forklift. What possible injuries could
occur?

8
 Unattended Forklift

What are the rules for an

unattended Forklift

Ask the group, what the requirements are for an unattended forklift.

25 feet away from the forklift

Not in view
Forks or other attachment lowered
Controls in neutral
Power shut off
Set the brake

Basic Safety

• Don’t travel forward with

the load raised
• Travel in reverse if the
forward view is obstructed
by the load

When traveling with a load raised you may not see a low overhead hazard like traveling
through a door opening.

9
 Basic Safety

– Don’t pin anyone between a

fixed object
– Don’t drive forward or back
up to anyone who is
standing in front of a fixed
object

Ask for any examples the group might have. Have a few examples if needed.

Basic Safety

Don’t pass under elevated

portion of the forklift

Have you seen this? What would you do if someone tried to pass under an elevated load?

10
 Basic Safety

• 90 degree turns
• Tail swing---Danger
Zone
• Rear wheels point
outward when turning

When anyone walks up to the side of the forklift be sure to stop and give them time to
move away from the forklift. What are possible injuries from being struck by a forklift or
running over a foot?

11
 Basic Safety

• Use three point technique for getting on and off

the forklift
• Travel forward with a load unless the load blocks
your view
• Stay three forklift lengths from other forklifts
• Always keep arms and legs inside the confines of
the forklift

1. Forklifts have steps with anti-slip surfaces and grab handles to provide three points of
contact while getting on and off the forklift. Many injuries occur while mounting and
dis-mounting forklifts.
2. If your vision is obstructed while traveling forward, you have to travel in reverse.
3. In some facilities three lengths would not be possible. Always allow safe working
distance between forklifts.
4. Ask why you need to keep arms and legs inside the confines of the forklift.
Tell stories to demonstrate these points of what you have seen.

12
Truck Related Topics
Operators Manual

Operating procedures,
warnings, precautions,
controls and
instrumentation are
listed in the operator’s
manual for the type of
vehicle operated.

You should have an operators manual for one of the facilities forklifts as an informational
guide. The operators manual contains valuable information on operator protection,
equipment and operating procedures. Refer to the table of contents. Ask your audience
if they know where to get the operators manual for their forklift.

Controls and Instrumentation

• Review the owner’s

manual
• Review control labels
and control functions
(Some controls are
marked, others may
not be)
• There is no continuity
in control functions
among manufacturers

Even two of the same model forklifts could be different. Ask someone in the class who
drives two forklifts if they are the same or how they are different.
This is very important if it’s the first time on a different forklift.

13
 Forklift vs. Automobiles

Exercise #1
Ask the class, “What are the differences between a forklift and a car?” Have your class
write down or discuss all the differences they can think of.
Then transition to the slide below for the answers.

Forklifts vs. Automobiles

Forklift Automobile
• 3-Point Suspension • 4-Point Suspension
• Poor Vision-Mast • Vision, good large
windows
• Rear Wheel Steering
• Front Wheel Steering
• Tail Swing
• Weight distribution
• Counterweighted
• Designed for passengers.
• Designed to lift, stack, tier,
etc.
• Weight 4 to 5 tons • Weight 1 to 1.5 tons

Discuss the differences:

Which ones were missed?
Talk about the differences of each point.

14
 Exercise

Exercise #2
Pass out the handout, have the group fill in the blanks.
Your copy of the handout is on page 32.

The purpose of this exercise is to prepare the audience for the next slide:
the Pre-Shift Inspection.

15
 Pre-Shift Inspection

1. All Fluid levels

2. Tires
3. Hoses, Belts, Cables
4. Mast, Forks, Attachments
5. Horn, Alarms
6. Steering, Brakes, Gauges, Controls,
7. Fuel, Battery level

Regulations require a pre-shift inspection must be done before each shift. This inspection
must be documented.

A check list works well. Show them your company checklist or use the
one provided on page 33.

Brakes, controls, lights and alarms should be checked once the forklift is started.

16
 Lifting Personnel

– Guard rails
– Secured to lift truck
– Controls attended at all
times
– Operator in seat when
raising/lowering
– No point-to-point travel
except at slow speed and
platform lowered
– Guard the mast (shear
point)
– WA requires tilt be secured

Discuss each point. Does your lifting basket include each of these?

Lifting Personnel

How many things do you see wrong with this picture?

17
 Stacking Material

• Stacking and un-

stacking on racks

While stacking and un-stacking on racks, pay close attention to clearances. Talk about
some of the issues you’ve seen at your facility.

Loading Docks

• Working around
loading docks

Extra caution must be used when working on a loading dock. Know where you and your
forklift are at all times.
• Make sure wheels are chocked/blocked when loading or unloading trailers.
• If you have a dock plate, make sure it is secured.
• If you are loading a trailer, walk inside the trailer and check the trailer floor.
• Make sure the trailer front is supported if the truck is not attached.
• Never leave a forklift running inside a trailer; you could have carbon-monoxide
buildup.

18
 Capacity

As operators, what’s the capacity of your forklift?

Ask the group, “How much weight do you think this forklift can lift?”

Capacity

Read the information on the data plate. This forklift is a remanufactured rigger special.
This forklift can lift 80,000 lbs. at 24 inch load center in first gear only.

19
 Capacity

Ask the group what could have happened in this picture. Did you notice how all four tires
are off the floor and the forklift is sitting on the main mast? The forklift was overloaded;
the operator tried to back up and turn with the load raised. The next slide will show you
what happened.

Capacity

This forklift was over capacity. The operator raised the load, backed up and turned at the
same time. The center of gravity moved outside of the stability triangle and the forklift
tipped over.
What is the Stability Triangle?

20
 Stability Triangle

• Most forklifts have a three-

point suspension system.
• These three points form a
triangle called the stability
triangle.

When the vehicle’s center of gravity falls within the stability triangle, the vehicle is stable
and will not tip over. When the center of gravity combination falls outside the stability
triangle, the vehicle is unstable and may tip over. This is one of the most important
concepts for you to know about operating a forklift.

Center Of Gravity

The forklift has a center of gravity and the load has a center of gravity. As a load is lifted,
the two form a combined center of gravity. As long as the combined center of gravity
remains inside the stability triangle the forklift will not tip over.
Demonstrate by using the chair exercise we used in the first part of the class.

21
 Center Of Gravity

Another way to look at it — the drive wheels act as a fulcrum point. A fulcrum point acts
like a teeter totter. The stability of any forklift is directly affected by the capacity.

Center of Gravity

The forklift center of gravity and the load center of gravity form a combined center of
gravity. As the load is lifted the combined center of gravity can move outside the stability
triangle if:
• The load is picked up on the tip of the forks
• The load is tilted forward
• The load is tilted too far back when raised
• The load is wide, or — forklift movement causes the center of gravity to shift
What happens if you go down a slope or up that same slope with the load lifted in the air?

22
 Center Of Gravity

Lateral stability is a truck’s resistance to overturning sideways.  

Dynamic stability refers to the idea that an unloaded forklift’s center of gravity and a
loaded forklift’s combined center of gravity can shift outside of the stability triangle as a
result of certain movements, such as sudden stops and starts, turns, or operating on
grades.

If you lift more than the forklift’s capacity, your back wheels will come off the ground.
What happens when you turn to the right with a load or turn to the left with a load?
Where will the center of gravity be when traveling up a slope or down a slope?

Determine a Load’s Center of Gravity

– Center of gravity is
the balance point CENTER OF 180LB TOP VIEW OF LIFT TRUCK
LOAD GRAVITY
– Load center is the point
where the heaviest part of
the load is located
– Pick up load on the side 300LB

closest to its center of CENTER OF GRAVITY

gravity LOAD CENTER

What happens to the Center of Gravity when we have a side heavy load? Does this affect
the combined center of gravity? The center of gravity is the balance point of the load. The
exact point on which the entire load will balance. For loads that are composed of
consistent material, the balance point will be near the center of the load. If the load is
inconsistent — that is, it contains materials of different weights and/or lengths — the load
center will be on the side with the heaviest material. For example, if a pallet contains
bricks on one side and pillows on the other, the center of gravity would be closer to the
side with the bricks.

23
 Tip Over Safety Procedure

• Always wear your seat

belt
• Hold onto the steering
wheel
• Brace your feet
• Lean away from the fall
• Keep your body inside
the cage

Have you seen anyone get close to the edge of a ramp? What should you do?

Forklift Fueling--Propane

• Shut down the engine while fueling. Use required PPE, gloves and
face shield. You should have long sleeves covering your arms.
• Handle all tanks and/ or hoses carefully. Propane can cause freezing
type burns if it comes into contact with skin.
• If you detect a leak, remove the forklift from service until repairs can
be made.

Extra precautions need to be taken with forklifts powered by propane. Has anyone
ever been burned by propane? Propane burns are similar to a bad frost bite. If you smell
propane anytime other than when you’re refueling shut the forklift off and contact a
supervisor. Never start the motor if there is a leak.

24
 Forklift Fueling—Diesel or Gasoline

• Shut the engine off while refueling

• Wear proper PPE, eye protection and gloves
• Make sure there are no open flames near by
• Make sure to use the correct fuel
• Replace cap when full and check for leaks

Cover each point.

Battery Charging

• The charging area must

have plenty of ventilation
• Wear PPE, eye protection
and gloves
• Make sure charger is off
before connecting it to the
battery

Cover each point

An eyewash or eyewash with shower must be available when doing battery service beyond
routine charging. Do you have plenty of ventilation at your facility? Does everyone wear
their PPE? Why should you wear long sleeve shirts? Always make sure the charger is off
before connecting the battery.

25
 Workplace Related Topics

Hazard Mapping

Exercise #3
Have your audience draw a schematic of their facility/location
Hand out the Site Specific Workplace Hazard Analysis guide
Your copy is located on pages 34-36.
Have the class fill in hazards on their map.
Examples:
Uneven surfaces, broken concrete
Blind corners
High pedestrian traffic by a break room or bathroom
Ramps and other sloped surfaces
What about closed areas with air flow restrictions
Could there be carbon monoxide build up?

26
 Ramps

Stay clear of ramp edges

Have you seen anyone get close to the edge of a ramp? What should you do?

Rail Road Tracks

• Drive diagonally across

tracks
• Park 8 feet 6 inches or
more from the center of
the tracks.

If this does not apply to your location skip to the next slide.

Why would you want to cross the tracks diagonally?

8 feet 6 inches or more, why not 8 feet?

27
 Overhead Clearances

• Overhead doors, pipes,

roof or any other overhead
hazards.

Has anyone seen this happen before? What about using a cell phone while operating a
forklift?

Traveling

– Look in the direction of travel

– Make sure load is fully engaged
– Keep forks low when traveling
– Sound the horn
– Don’t speed
– Check clearance

Discuss each point:

These sound like common sense but remember the statistics:

• 10% of fatal accidents are struck by or run over by a forklift

• 42% of fatal accidents are forklift overturns

28
 Operator Evaluation

• After initial training

• After refresher training
• At least once every
three years

All operators must have their driving skills evaluated to ensure desired performance at
least every three years.

This is a good time to discuss requirements for refresher training:

• Unsafe observation observed
• Accident or near miss
• Evaluation indicates need
• Different type of equipment
• Workplace conditions change
Sample form on pages 37 and 38.

29
 Pedestrian Awareness

• Tail Swing
• Braking Distance
• Visibility
• Walk Ways

Ask the group, if pedestrians should be trained about forklift hazards.

Tell stories to demonstrate these points of what you have seen.

Pedestrian Traffic

• Always keep walk ways

clear
• Who has the right-of way,
the forklift or the
pedestrian?

Does your facility have clear painted walk ways for pedestrians? If not how does your
facility handle traffic?
Discuss who has the right-of-way at your facility.

30
 We’re in this together.
QUESTIONS?

• Time for a Test

Hand out test

Score the test how you want
Your copy and answer sheet are located on pages 39 and 40.

31