Forklift Operator Training
29 CFR 1910.178

Is Forklift Training Necessary?
 About 100
deaths each year
 About 95,000
accidents each year
 Bankruptcy
 New OSHA
training standard

Forklift Operating Goals
 Hazards and forklift stability
 Inspecting and operating a forklift
 Quiz

Authorized Operator
 Only trained and authorized personnel are
permitted to operate a forklift
 Keep unauthorized employees off of forklifts
 Keep pedestrians away from the operating
zone of a forklift
 Lock out unsafe lifts as determined in a
preoperation inspection

Operating Hazards
 Workplace hazards: ramps, railroad tracks,
slippery floors, poor lighting, congestion
 Loads: large or bulky, uneven weight, broken
pallets, poorly stacked
 Pedestrians: horseplay, unaware of forklift
areas, not paying attention

Nameplate
 OSHA requires a legible nameplate
 Includes modifications & attachments
 Capacity
 Load center

Center of Gravity
 Balance point
48”
A
B
20” 40”
 Distance from the edge of the
item to the item’s center of gravity

Load Center
 Distance from vertical face of the forks
to the load’s center of gravity
–A: Load center = 24"
–B: Load center = 40" 80”
B
48””
A
 1 inch = 100 lbs
 Important reason for keeping the load
resting against the vertical face of forks

Stability Triangle
3-point suspension
 Forklift’s center of gravity
 Combined center of gravity
 Load center beyond 24"

Combined Actions
 Center of gravity moves
side to side
 Center of gravity
moves forward
 Center of gravity moves
backward to the thin portion
of the triangle

Attachments
 Specific
operator training
 Weight of
attachments
 Increased
load center

Tipping Over
 Do not jump
 Hold onto the steering wheel
 Brace your feet
 Lean away from the fall

Forklift Operating Goals
 Hazards and forklift
stability
 Inspecting and
operating a forklift
 Quiz

Preoperation Inspection
 As an authorized operator,
it is your responsibility to
make sure your forklift
functions properly
 OSHA requires
preoperation inspections
 Company wants to comply
with OSHA and be sure
equipment is maintained

Walk Around
 Forklift properly disengaged
–Forks down, key off, neutral gear, parking brake on
 Left/right side
–Tire condition, tight lug nuts, no debris around axle,
overhead guard is solid, no debris behind the mast
 Front
–Forks in good shape, fork pins in place, backrest
solid, mast & chains greased, hoses in good shape
 Rear
–Counterbalance bolt is tight, radiator clear of debris

In the Seat
 Nonmoving checks
–Gauges, lights, horn, back-up alarm, blinking
warning light, operate the tilt & lift mechanism,
check the parking brake
 Moving checks
–Put on the seat belt, check the running brakes,
check the steering
 Look for oil or water leaks on the floor

Operating a Lift Truck
 Only trained, authorized operators
 Immediately report forklift-related accidents
 Seat belts must always be worn
 No person should stand under elevated
portion of lift truck
 Forklift controls operated only from
driver’s seat
 Never block exits or emergency equipment
 Smoking is not permitted

Loading/Unloading
 Before raising a load, understand:
–Approximate weight of the load
–Location of the load’s center of gravity
 Inspect load for stability, projections,
damaged pallets before lifting
 Restack unstable loads
 Never place weight on the back of
a lift truck to increase its capacity
 Towing always done from rear towing pin

Traveling
 Always look in the direction of travel
 Keep body inside the cage
 When moving, the mast must not be raised
 Sound the horn
 Operate at safe speeds
 When turning, watch rear end swing
 Clearance under overhead installations

Traveling (cont.)
 Avoid loose objects or holes
 If load blocks view, travel in reverse
 Never carry passengers
 Pedestrians always have the right-of-way
 Safe distance from edge of ramps or docks
 Never eat or drink
 No stunt driving or horseplay

Ramps and Railroads
 Never turn on a ramp
 On ramps the load should be upgrade
 Ascend or descend ramps slowly
 Railroad tracks are crossed diagonally
 Never park within 8 feet of the center of
railroad tracks

Docks
 Inspect the dock plate
 Check the trailer floor condition
 Trailer wheels are chocked
 Nose of the trailer is supported
by the tractor or a fixed jack

Parking
 Lower the forks
 Set gear to neutral
 Set the parking brake
 Turn off the key

Propane Refueling
 Propane is a combustible, compressed gas
 Propane leaks are detected by:
–Distinct odor
–Hissing sound
–Frost on fittings
 PPE: gloves, safety glasses

Battery Charging
 Inspect battery connectors for damage
 No smoking in battery-charging area
 Immediately clean up electrolyte spills
 PPE includes face mask, acid-resistant
gloves, and an apron

Forklift Operating Goals
 Hazards and Forklift Stability
 Inspecting and Operating a Forklift
 Quiz

Summary
 Facility hazards
 Load center and capacity
 Preoperation inspection
 Rules of the road
 Refueling

Quiz
1. If your forklift has a rearview mirror,
looking behind you is not necessary. True or False
2. Name two of the three ways to detect
a propane leak: _______________, _______________
3. Describe the four items that must be completed
prior to driving your forklift into a trailer.
4. If a load blocks your vision, it is OK to raise
the load while moving to see under it. True or False
5. Preoperation inspections are done only
because OSHA says we have to do them. True or False

Quiz (cont.)
6. Attachments reduce capacity by increasing
the load center and adding weight. True or False
7. Minimum PPE items required when refueling
a propane tank are ___________, ____________.
8. The most important differences between a
forklift and a car are weight and steering.True or False
9. Name at least one condition that when
combined with turning sharply may cause a tipover.
10. Pedestrians have the right-of-way only
while in designated pedestrian lanes. True or False

Quiz Answers
1. False. You must always look behind you before
backing up.
2. Hissing sound, distinct odor, or frost on fittings.
3. Chock the wheels, support the nose of the trailer,
inspect the dock plate, check the trailer floor.
4. False. Never drive with the load up. Drive in reverse
when the load obstructs forward vision.
5. False. Inspections are also done so that the operator
can prevent mechanical failure accidents and because
the company needs to prove compliance with OSHA’s
requirement.

Quiz Answers (cont.)
6. True. Attachments are heavy, and they cause
the load center to move away from the forklift.
7. Gloves and safety glasses are the minimum PPE
required.
8. True. There are many differences, but the most
significant are weight and steering.
9. Hitting a pothole, carrying an off-center load,
getting a flat tire, having a raised & tilted back
load, or being on a ramp.
10. False. Pedestrians always have the right of way.