A short refresher course in safe forklift operation. available for presentation online or at your workplace with checklists, planning, scheduling tips and information. contact Eric at erickay84@gmail.com

1. FFoorrkklliifftt OOppeerraattoorr
- Refresher Training Course
Eric L Kay, Safety Specialist
Kay Associates
CCoommppaannyy::
Operations at:
Kay Associates 1
© 2002 – 2014
SSeeyymmoouurr SSeerrvviicceess
Campbell River, B.C.

2. Forklift Training
Presented by:
Eric L Kay, Facilitator
Kay Associates WWW.KAYASSOCIATES.COM
With materials sourced from:
British Columbia Workers Compensation Board
WWW.WORKSAFEBC.COM
Canadian Center for Occupational Health and Safety
WWW.CCOHS.CA
OSHA
http://www.osha.gov/
Finning (Canada)
WWW.FINNING.CA
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3. Contents / Overview
 Background
 Relevant Legislation – WCB, Motor Vehicle Act
 Fundamental Safety Guidelines, Rules and Safety codes
applicable to work at jobsite.
 Safe operation of Forklift
 Main components of lift trucks.
 Owners Manual to be used as part of the training.
 Operational Maintenance (inspections / fuelling)
 Basic operating principles - Lifting, Steering, Maneuvering,
Traveling, Load Handling,
 Operating limits, vehicle capacity, vehicle stability, Operating
surface conditions, Identification of hazards,
 Operational (hands-on) Training
 Certification of operators
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4. Regular Inspection or Repair
- Log book
Equipment Log Book should contain
a daily record of;
 Date of Inspection.
 List of Work required.
 Date of Repair
 When repair work is scheduled. date and time
 When repair work has been completed. dated and
signed
Suggestion – create and track a logbook using company work
order system – automatically trigger updates!
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5. General Guidelines
- Instruction
Prior to operating any piece of equipment or
machinery,
 Read the operators manual for specific information
concerning the machine including;
 the controls, (how they work)
 safety devices, (how they operate)
 Participate in or receive instruction on;
 How to perform tasks in a safe manner,
 The location and terrain that you will be working in
 cautions about the work area,
 jobs and tasks to be performed,
 Safety concerns with other workers, equipment or
machinery in your work area.
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6. General Guidelines
- Safety clothing and equipment
 Use safety clothing and equipment that
is appropriate for the jobs and tasks that
you will be performing and appropriate to
the work environment.
 Some examples;
•Hard hat,
•Visi-vest,
•Steel toes,
•Eye protection,
•Hearing protection,
• Hand protection (gloves)
•_____________________
•_____________________
•_____________________
• Add others specific to your
equipment and working location
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7. General guidelines
- Personal health
 Do not operate equipment or machinery under the
influence of any mind/body altering substances. (please
note that this does include prescription medicines and
over-the-counter medications such as cold remedies)
 If you are fatigued or If you feel drowsy, stop operations,
shut off machine and get off the machine. Note: while
walking and/or coffee may possibly be used to awaken
yourself, adequate rest is the only cure for fatigue.
 Constant turning, circling or weaving OR flashing bright
lights(sunlight) can induce levels of vertigo and
disorientation. Stop, get off the machine and rest.
 Do not be a safety risk to yourself or to others. DO NOT
operate machinery or equipment when you are in an
unsafe health condition.
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8. GGeenneerraall gguuiiddeelliinneess
-- SSaaffee EEnnttrryy // EExxiitt
 Use three points of contact when entering or
exiting machine. Eg. use handrails, steps and
foot-holds.
 Carefully step down, do not jump. – jumping is
identified as a cause in many cases of slips and falls.
 In case of electrical powerline contact, stay in
your machine – DO NOT get out, stay in the
seat, wait for the power to be turned off and
you are told it is safe to exit the machine.
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9. General Guidelines
NO riders
NO unsafe operation
 NO riders on the body of the
machine!
 NO riders on the forks or on the
load!
 NO hoisting of personnel on the
forks or on the load or on a
makeshift platform!
 NO use of a fork as a lifting hoist!
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10. Forklift Components
Steering and operator controls
SEAT BELT !
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11. Safety Inspections
- General
 Conduct a walk-around before you start the machine.
 Your safety inspection check should include (but not be
limited to) the following;
 Safety guards in place
 Fluid levels - water, engine oil, hydraulic oil,
 Fuel Level,
 Tires / Tracks
 Rubber, Pressures, Wheel lugnuts
 Excessive wear and/or Damage
 Steering,
 Braking,
 Lights, safety indicators/beacons
 Safety back-up alarm operating.
 Damage to any part of the machine.
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12. Safety Inspections
- Fork Safety
Under normal operating conditions; forks should be visually
inspected:
 Daily: Operators should make visual inspection of forks during
the pre-start-up check, giving special attention in looking for
excessive wear, distortions(bending) or cracks.
 One to Six months: A thorough inspection of forks should be
done by a trained person to check for; wear, cracks or
distortion(bending). NOTE: Forks may need inspections more often,
depending on the use of the equipment.
 If forks are bent or damaged – Do not use!
 Fork holding pins and fork locks should be in good condition.
Ie. not loose, bent or damaged - Do not operate if pins or locks
are missing.
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13. Kay Associates 13
Do’s
and
Dont’s
Forklift Operation
- Seat Belt
 Always
 Always - Put on and fasten the seat belt before you operate
the machine.
 Always – Keep the seat belt snugly tight - wear seat belt
in a secure and well adjusted manner.
 Always - Keep the seat belt fastened while operating the
machine.
 Never;
 Never - Run the machine with seat belt unfastened
 Never - Undo the seat belt if the machine starts to tip over.
 Never - Undo the seat belt if the machine starts go off the end
of a loading dock.

14. Kay Associates 14
Do’s
and
Dont’s
Forklift Operation
- Load Handling
 Do not exceed the recommended
load limit.
 Position the load according to the
recommended load centre.
 Keep loads close to the mast (front wheels) to
prevent overbalancing.
 Travel with load close to the ground
 Keep center of gravity low to prevent tipping
 Raised loads and mast can contact overhead
obstructions/wires

15. Forklift Operation
- How should you insert the fork?
 Ensure that the load is secured before moving.
 Space the forks properly.
 Center the forks on the weight load balance point.
 Don’t travel with an unbalanced load.
 STRAP yyoouurr llooaadd sseeccuurreellyy !!!!!!
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Do’s
and
Dont’s

16. Forklift Operation
- How should you raise the load?
 Check that the overhead clearance is adequate before
raising loads.
 Lift loads straight up (preferably tilted back slightly).
 Do not lift a load that extends above the load backrest
unless, under no circumstances, no part of the load can
possibly slide back toward the operator.
 Attend the controls of the forklift truck when a load is
elevated. In other words, the operator must stay on the
forklift when the load is in a raised position.
 Raising the load decreases the stability of the forklift,
increasing the likelihood of tipping !
 Do not allow any person to be under the load – AT ANY
TIME! – FOR ANY REASON!
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Do’s
and
Dont’s

17. Forklift Operation
- How should you drive the forklift?
 Changes in the center of gravity and likelihood of
tipping are affected by;
 Higher speeds.
 Cornering.
 Sloped or angled surface.
 Incline (Up a hill or down a hill). Be sure to travel with the load facing uphill.
 Raised loads.
 When traveling - Carry the load low down. – for stability – for visibility
 Be extra careful when visibility is blocked or impaired ! – use a spotter!
 Start, Stop, Travel, and Turn in a careful and controlled manner.
 Look before backing up.
 Do not allow passengers.
 Do not use forks as a man-lift.
 Observe capacity rating – do not overload!
 Shutdown and parking – Set park brake, Lower forks to ground, Turn key off.
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Do’s
and
Dont’s

18. Forklift Operation
- Loading and Unloading Vehicles
 What action should you take before you load
and unload a vehicle or trailer. Brake’s set?
 How should you prepare the work area for
using a forklift truck for loading/unloading
operation? Clear work area of obstacles
 What should I do before loading or unloading a
trailer at a loading dock? Block wheels of the
trailer.
 When loading railway cars, what is important to
know? Block wheels
 What should I do when using a forklift truck in
an elevator? Turn off ignition
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Do’s
and
Dont’s

19. Maintenance
· Do not work beneath
elevated forklift
trucks or forks unless
they are securely
supported by an
approved blocking
device. A chunk of
wood or steel for a
temporary support is
not a satisfactory
substitute!
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Do’s
and
Dont’s

20. Stability Triangle
- Figure 1
 When the vehicle is loaded, the combined center
of gravity (CG) shifts forward toward line B-C.
 Theoretically the maximum safe load will result in
the CG at point just behind the line B-C.
 In actual practice, the “loaded” CG should never be at line B-C as a load weight is required on the steering axle. –
always there should be sufficient weight to safely steer the machine when traveling, even over humps and bumps
and braking (applying machine brakes brings center of gravity forward. Also going downhill brings the center of
gravity forward – so if the machine is to operate on grades the machine should back down the hill).
 Loss of steering control is a factor in many forklift accidents.
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A
B
C
Vehicle Center of
Gravity (Unloaded)
Center of Gravity
of Vehicle with
Maximum Safe Load
X
Vehicle is UN-SAFE
when center of
Gravity approaches
front wheels

21. Stability Triangle
- Figure 2
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Load CG
Vertical
Stability
Line
(Line of Action)
Combined CG
Truck CG
This vehicle is stable
Load CG
Combined CG
Vertical
Stability
Line
(Line of Action)
Truck CG
X
This vehicle is unstable and
will continue to tip over
Caution: Lift trucks have a very poor stability tolerance for side slopes
Do not turn on a slope and do not run across a slope.

22. Stability Triangle
- Figure 3
 Always travel with the
load facing uphill;
 Forward uphill
 Backward downhill
 Travel with the load as
low down as possible
 A small obstruction such
as a low curb can upset
your balance or shift your
load
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23. Propane
– Changing Tank
 Check replacement tank for damage or
deterioration & check expiry date.
 Check hose for damage or wear.
 Wear gloves and safety glasses when
disconnecting hoses / tanks.
 Only change tank;
 in a well-ventilated area.
 well away from any source of ignition.
ALWAYS: Refer to OWNERS MANUAL for
detailed & specific instructions
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24. Common Factors in Forklift Accidents
- Work Organization
 Lack of training or improper training
of workers who have to operate
forklift trucks.
 Production factors such as speed or
stress.
 Lack of proper tools, attachments
and accessories.
 Improper use of forklift.
 Poor or lack of maintenance of
forklifts.
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Page 1 of 5

25. Common Factors in Forklift Accidents
- Behavioral and Operational
Factors
 Failure of operator to put on the seat belt. (and loosely adjusted
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seat belt)
Page 2 of 5
 Operator jumping from a machine that is tipping over or
going over the end of a loading dock
 Improper backing up techniques.
 Improper turning.
 Improper warnings to others about a forklift in use nearby.
 Poor communication during shared tasks, or in shared
spaces.
 Riding or giving rides on forklift cab / step or on the forks or
on the load.
 Parking the forklift improperly.
 Improper blocking of wheels on semi-trailers or railway
cars.
 Horseplay; stunt driving; jerky, erratic driving.

26. Common Factors in Forklift Accidents
- Workplace Design
 Narrow aisles.
 Crowded, cluttered aisles.
 Obstructions at intersections and doors.
 Volume of traffic in work area.
 Other persons walking and/or working in the general area
of forklift operations.
 Adverse workplace conditions such as noise, odours, toxic
gases, dust, weather, or poor lighting.
 Many ramps with different surfaces.
 Condition of loading dock.
 "Blind spots" or obstructions blocking
the driver's view.
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Page 3 of 5

27. Common Factors in Forklift Accidents
- Characteristics of the Load
NO,,,,,,,,,,,,,,,
 Load carried on tip of forks.
 Load not all the way back against the mast.
 Poorly stacked or poorly piled on the pallet.
 Pallets in poor repair.
 Load too heavy. (forklift overbalancing)
 Load unstable;
 Loose or unsecured materials on pallet.
 Heavy on one side.
 Load blocking drivers vision.
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Page 4 of 5

28. Common Factors in Forklift Accidents
- Mechanical Conditions Page 5 of 5
 Malfunction of brakes. - Foot brake - Park brake - Brake lock
 Malfunction of steering. - Power steering - Steering linkage
 Wheels/Tires – Wheel nuts loose or broken – Poor tire condition.
 Malfunction of clutch, shift linkage, or transmission.
 Fork failure – Bent, cracked or worn forks.
 Malfunction of mast assembly;
 Pin breaks or mast cracks and fails. (rare)
 Chain breaks. (common)
 Hydraulic hose breaks. (common)
 Leaks in hydraulic systems or transmission.
 Safety devices lacking, inadequate, or malfunctioning.
 Exhaust emissions from forklifts.
 Lights / Warning Lights - Damaged or inoperative.
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29. Hazards in the operating
environment
Location: ______________________
Yard & Storage Areas
 Building - Low roof, exhaust fumes, visibility(crushing injury).
 Other workers in operating area.
 Trucks in operating area also being loaded at same time.
 Tipping
 What are your in-house hazards??
Street
 Pedestrians.
 Vehicle traffic.
 Blocked or reduced visibility.
 Power lines
 What are your street hazards??
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30. Daily Checks &
Operator pre-use check
 Bolts, nuts, guards, chains, or hydraulic hose reels not damaged,
missing or loose.
 Wheels and tires -- check for wear, damage, and air pressure if
pneumatic tires.
 Forks – not bent; no cracks present; not worn down; positioning
latches in good working condition; carriage teeth not broken, chipped
or worn.
 Chain anchor pins -- not worn, loose or bent.
 Fluid Leaks -- no damp spots or drips.
 Hoses -- held securely; not loose, crimped, worn or rubbing.
 Horn -- working and loud enough to be heard in working
environment; other warning devices operational.
 Lights -- head lights and warning lights operational.
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Page 1 of 3

31. Daily Checks &
Operator pre-use check
 Fire extinguisher – present and charged.
 Engine oil level, Radiator water level, Fuel level (LPG,
gas and diesel forklifts).
 Foot Brake -- pedal holds, unit stops smoothly.
 Parking Brake -- holds against slight acceleration.
 Deadman Seat Brake – holds when operator rises from
seat.
 Clutch and Gearshift – operates and shifts smoothly with
no jumping or jerking.
 Dash Control Panel -- all lights and gauges are
operational.
 Steering – moves smoothly, no looseness or slow
response.
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Page 2 of 3

32. Daily Checks
Operator pre-use check
 Lift Mechanism -- operates smoothly (Check by raising forks to maximum
height then lowering forks completely.)
 Tilt Mechanism -- moves smoothly, holds (Check by tilting mast all the way
forward and backward.)
 Cylinders and Hoses -- not leaking after above checks.
 Mast – Not loose and sloppy, no visible cracks
 Chain – appears to be in good condition? Is one side loose?
 Wheel nuts appear tight.
 Check forks for bending, cracks or undue wear.
 Check pins for wear. (use proper pins – not any old bolt)
 Listen for any unusual sounds or noises.
 Do not operate forklift if deficiency is found
 Tag it Out: Clearly identify the machine as non-operational
 Isolate it: Remove the ignition key and tag-out the key also
 Report any problems identified in checks to supervisor immediately
 Supervisor to arrange necessary repairs on a timely basis
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Page 3 of 3
Modify this list for your use, or Create a specific checklist

33. Common Types of Fork Lifts
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Stacker
Straight Mast Rough Terrain TeleHandler

34. Inspection of Work Place
for Hazards
 Pre-inspect the work area for
hazards - a) before the job bb)) daily
 Eliminate the hazards,
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or
 Minimize the hazards.
 Examples of hazards
 Protruding product from storage areas
 Grease/oil on the floor
 Uneven floor, aisles or roadways
 Overhead obstructions
 Height restrictions
 Restricted visibility areas
 Casual or general public foot traffic
 Damaged storage racks
 Doors in walls that open and provide foot
or vehicle access to traffic areas
 Door height restrictions
 Blind corners
 (can you list additional hazards?)
____?______________________
_____?_____________________
______?____________________
_______?___________________
________?__________________
_________?_________________

35. Maintaining Forklift Control
 handling pallets?
 Insert forks fully
 lifting, tilting, and stacking a load?
 Move slowly, and carefully – avoid jerky movements
 when traveling?
 Keep load close to the ground
 traveling up or downhill?
 Keep the load uphill
 park the forklift truck?
 Apply parking brake
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Self test
As a safe operator, what should you do when;

36. Professional
Operator
 Who can operate the forklift?
 Trained and experienced operator authorized by employer
certificate.
 What should an operator do when operating the forklift truck?
 Observe all safety guidelines.
 What should an operator avoid when operating a forklift
truck?
 Avoid all the DON’T”S of operating a forklift.
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Self test
 Who can operate the forklift?
 Trained and experienced operator authorized by employer
certificate.
 What should an operator do when operating the forklift truck?
 Observe all safety guidelines.
 What should an operator avoid when operating a forklift
truck?
 Avoid all the DON’T”S of operating a forklift.

37. Safe Handling of Propane
(LPG) Fuel
 What should an operator do when handling
propane fuel?
 Wear gloves and eye protection.
 What steps should operators follow when changing
propane fuel tanks?
 Close valves
 What should an operator not do when changing a
propane tank (cylinder)?
 Smoke a cigarette, or allow smoking nearby.
 Follow manufacturers recommendations – Operators Manual
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Self test

38. Batteries
 Why should you follow safety precautions when charging
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batteries?
– Danger of Fire and Explosion
 What are some precautions to use when handling battery acid?
– Gloves and face protection
 What do I do if someone gets sulfuric acid on their skin?
– Flush with water, get immediate medical aid.
 What do I do if someone gets sulfuric acid in their eyes?
– Flush with water, get immediate medical aid.
 Why is there a danger of exploding batteries?
– Batteries give of a vapour that in right concentrations can explode
 What should I do when charging batteries?
– Follow the manufacturers instructions – See operators manual
 What should I do when servicing batteries?
– Follow the manufacturers instructions - See operators manual
Self test

39. OOPS!
”Investigate” these
accidents. Discuss the
issues & how you
would prevent them
from happening
Unsecured load
Driving off the dock
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Speed Stopping
Not looking
Uneven surface
Raised load
Travelling sideways
Across a slope
Unstable
load
Not tilting forks back
Note: All examples were taken from actual accident investigations

40. Forklift Operator
Refresher Training Course
FFOORRMMAALL TTEESSTT
SSTTUUDDEENNTT:: Please open the test on your computer, tablet or
phone and answer the questions.
This is an “open textbook” test – you may refer back to the
class-room materials, ask the instructor or your employer,
or search the internet.
Once you have completed the test, please email the test as an
attachment to your employer and to the instructor.
EEMMPPLLOOYYEERR:: Please discuss the test answers with the
student while lending guidance. Upon your satisfaction,
issue the student with his/her “SAFE FORKLIFT
OPERATION” card.
Eric L Kay, Facilitator.
erickay@kayassociates.com
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© 2002 - 2013