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Safety Training Presentations. FORKLIFT OPERATOR SAFETY TRAINING. 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

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Safety Training Presentations

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Safety training presentations

Safety Training Presentations


Forklift operator training

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

Forklift safety hazards

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

Pre use inspections

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

Pre use checklist







Battery/LP Tank



Engine/Drive Motor




Seat belt

General overall condition of the forklift

Pre-Use Checklist

Pre use inspection lift mechanisms

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

  • Pre use inspection lift mechanisms1

    Pre-Use Inspection - Lift Mechanisms

    • Inspect all lift and tilt cylinders

      • Leaks

      • Mounting hardware

  • Inspect tires

    • Excessive wear

    • Proper inflation (if not solid rubber)

  • Propane tank inspection

    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

  • Changing propane tanks

    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

    Battery charging

    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

    Capacity plates

    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

    Starting the forklift

    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

    Operating the forklift

    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

    Handling and moving loads

    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

    Stability triangle

    Stability Triangle

    Stability triangle1

    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

    Fulcrum point

    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

    Tipping forklift

    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

    Handling and moving loads1

    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

    Handling and moving loads2

    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

    Handling and moving loads3

    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

    Stacking and unstacking

    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

    Stacking and unstacking1

    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

    Stacking and unstacking2

    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

    Stacking and unstacking3

    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

    Driving with a load

    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

  • Driving on inclines ramp slope

    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

    Stopped forklift

    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



    • 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



    • 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

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