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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

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 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