This document provides training on safe forklift operation. It outlines the objectives of the training program which are to qualify operators, teach safe operating rules, and prevent accidents and high maintenance costs. It covers causes of accidents and fatalities, the qualification program requirements, operating rules including inspections, load handling, travel, and unattended equipment. Trainees learn how to identify potential hazards and properly operate and maintain forklifts.

1. FORKLIFTFORKLIFT
OPERATOR QUALIFICATIONOPERATOR QUALIFICATION
PROGRAMPROGRAM

2. Objectives of this courseObjectives of this course
• To become qualified to operate a forkliftTo become qualified to operate a forklift
(aka forktruck or Powered Industrial Truck)(aka forktruck or Powered Industrial Truck)
• Learn the rules for safe operationLearn the rules for safe operation
• How to avoid forktruck accidentsHow to avoid forktruck accidents
• How to prevent high maintenance costHow to prevent high maintenance cost
• Verify your understand of what you learnedVerify your understand of what you learned
with a quizwith a quiz

3. Causes of AccidentsCauses of Accidents
0
5
10
15
20
25
30
Tipover
S
truck
by
truck
S
truck
by
falling
load
E
levated
em
ployee
R
an
offdock
Im
properm
aintenance
Lostcontrol
Truck
struck
m
aterial
O
vercom
e
by
C
O
Faulty
truck
U
nloading
unchocked
trailer
Fellofftruck
Im
properuse
E
lectrocuations

4. Causes of FatalitiesCauses of Fatalities
0
5
10
15
20
25
30
35
40
45
C
rushed
by
tipping
truck
C
rushed
betw
een
truck
and
object
C
rushed
betw
een
2
truck
S
truck
by
orran
over
S
truck
by
falling
m
aterial
Fallfrom
platform
on
forks
A
ccidentalactivation
ofcontrols

5. Qualification ProgramQualification Program
• This program is not designed to "teach"This program is not designed to "teach"
employees how to operate a forklift.employees how to operate a forklift.
• It is intended only to confirm the safetyIt is intended only to confirm the safety
aspects of forklift operation for thoseaspects of forklift operation for those
people already familiar with its operation.people already familiar with its operation.

6. Who Can Use A Lift Truck?Who Can Use A Lift Truck?
““Only trained and authorized personnelOnly trained and authorized personnel
shall be permitted to operate forklifts.”shall be permitted to operate forklifts.”

7. Training requirementTraining requirement
• Phase 1: Classroom instruction & quizPhase 1: Classroom instruction & quiz
• Phase 2: Observation of the trainee operating aPhase 2: Observation of the trainee operating a
trucktruck by a person experienced in forklift operationby a person experienced in forklift operation
Notes about Phase 2:Notes about Phase 2:
– training must not endanger the trainee or othertraining must not endanger the trainee or other
employees.employees.
– the observation must be completed on each truck thethe observation must be completed on each truck the
employee will be assigned to operate.employee will be assigned to operate.

8. Refresher training is required when . . .Refresher training is required when . . .
• The operator has been observed operating in anThe operator has been observed operating in an
unsafe mannerunsafe manner
• The operator is involved in an incident or near-The operator is involved in an incident or near-
missmiss
• The operator is assigned to operate a different typeThe operator is assigned to operate a different type
trucktruck
• A condition in the workplace changes in a mannerA condition in the workplace changes in a manner
that could affect safe operation of the truck.that could affect safe operation of the truck.
• At least every 3 years.At least every 3 years.

9. HIGH ACCIDENT &HIGH ACCIDENT &
MAINTENACE COSTSMAINTENACE COSTS
Are usually results of :Are usually results of :
• Safety rule violationsSafety rule violations
• Near missesNear misses
• Hot-DoggingHot-Dogging
• Lack of inspectionsLack of inspections

10. General RequirementsGeneral Requirements
• Modifications or additions to forklifts mustModifications or additions to forklifts must
be approved, in writing, by the manufacturerbe approved, in writing, by the manufacturer
• Name plates must reflect all front-endName plates must reflect all front-end
attachmentsattachments
• Nameplates must be in place and legibleNameplates must be in place and legible

11. • Truck shall not be used around flammableTruck shall not be used around flammable
vapors or hazardous concentrations of metalvapors or hazardous concentrations of metal
dustdust unless they are designated as a DY,unless they are designated as a DY,
EE, or EXEE, or EX
• Attention should be paid to carbonAttention should be paid to carbon
monoxide (CO) levels in work areas wheremonoxide (CO) levels in work areas where
truck are operatingtruck are operating
General Requirements (cont.)General Requirements (cont.)

12. Load CenterLoad Center
Load center

13. MAXIMUM LOADMAXIMUM LOAD
• There will be several weights stenciled onThere will be several weights stenciled on
the nameplate.the nameplate.
• The weights listed will be with the uprightsThe weights listed will be with the uprights
vertical and the center of gravity of thevertical and the center of gravity of the
load at various distances from theload at various distances from the
backrest.backrest.

14. 4350# with load center 24” from backrest
24 4350

15. Name PlateName Plate
Capacity Load Center
Tire size
Tire press
2490 cap when load center
is 20” from backrest 2190 cap when load center
is 30” from backrest

16. Important!Important!
The higher the lift,The higher the lift,
the lower the capacitythe lower the capacity

17. Movement of the stability triangleMovement of the stability triangle
1. Truck
stopped, no load
2. Truck is loaded or
stopped quickly
3. Truck is loaded on
right side or turning left
4. Truck is
loaded on left
side and/or
turning right
5. Truck is loaded and
lifting a load with the
mast titled back
Stability Triangle

18. Key points about the stability triangleKey points about the stability triangle
• If you get outside the stability triangle, the truckIf you get outside the stability triangle, the truck
could turn overcould turn over
• No quick stops or turnsNo quick stops or turns
• Keep load lowKeep load low
• Inch slowly when load is lifted for depositInch slowly when load is lifted for deposit
• Keep loads stable on forks so they don’t shiftKeep loads stable on forks so they don’t shift
• Creep when carrying containers of liquidCreep when carrying containers of liquid
• Tilt back no more than necessaryTilt back no more than necessary

19. SURVIVING A TIP-OVERSURVIVING A TIP-OVER
• Don’t jumpDon’t jump
• Hold on to steering wheel tightlyHold on to steering wheel tightly
• Brace feet with wide stanceBrace feet with wide stance
• Lean away from the tip directionLean away from the tip direction

20. REAR-END STEERINGREAR-END STEERING
• Due to rear-end steering,Due to rear-end steering,
operators must slow downoperators must slow down
in order to watch the tailin order to watch the tail
swing and the tips of theswing and the tips of the
forks at the same time.forks at the same time.
• You can’t do this if yourYou can’t do this if your
driving too fast.driving too fast.

21. ClarkClark
What’s wrong in this picture?
Load is way
to high
Stopped
too fast!
Load height is
O.K. if stopped
to stack, right?
Maybe should
be driving
backwards
Driver not at the
controls

22. FORKSFORKS (CONT.)(CONT.)
• When a forklift isWhen a forklift is
not in use, the forksnot in use, the forks
must be groundedmust be grounded
and leveled.and leveled.
nono
yesyes

23. FORKS (CONT.)FORKS (CONT.)
• Under no circumstancesUnder no circumstances
should anyone be allowedshould anyone be allowed
under raised forks,under raised forks,
whether loaded or empty.whether loaded or empty.
• This includes fingers &This includes fingers &
toes.toes.

24. ELEVATION OF FORKSELEVATION OF FORKS
• When traveling on level surfaces the forksWhen traveling on level surfaces the forks
should never be raised more than about 4”should never be raised more than about 4”
from the floor or ground.from the floor or ground.
• When on unlevel surfaces, the forksWhen on unlevel surfaces, the forks
should not be raised any higher thanshould not be raised any higher than
necessary to clear the ground.necessary to clear the ground.

25. TRUCK INSPECTIONSTRUCK INSPECTIONS
• Forklifts shall be examined before being placedForklifts shall be examined before being placed
in servicein service
• Trucks must be inspected at the end of eachTrucks must be inspected at the end of each
shift when used around-the-clockshift when used around-the-clock
• Trucks used intermittently must be inspected atTrucks used intermittently must be inspected at
the beginning of each day that the truck is usedthe beginning of each day that the truck is used
• Daily inspections shall be retained for 45 daysDaily inspections shall be retained for 45 days
• Monthly inspections shall be retained for atMonthly inspections shall be retained for at
least 13 months.least 13 months.

26. INSPECTIONSINSPECTIONS (cont.)(cont.)
The inspection must at least include theThe inspection must at least include the
following :following :
A. Leaks (water, fuel, hydraulicA. Leaks (water, fuel, hydraulic
fluid, etc.)fluid, etc.)
B. Tire damage and adequateB. Tire damage and adequate
inflationinflation
C. Faulty operation of controlsC. Faulty operation of controls

27. D. Brake condition (service and emergencyD. Brake condition (service and emergency
brakes)brakes)
E. Proper steeringE. Proper steering
F. Proper accessory operation (horn, lights,F. Proper accessory operation (horn, lights,
ignition switch, etc.)ignition switch, etc.)
G. Proper operation of lift/tilt mechanismsG. Proper operation of lift/tilt mechanisms
INSPECTIONSINSPECTIONS (cont.)(cont.)

28. H. Defects in forksH. Defects in forks
I. Battery chargingI. Battery charging
J. Fuel connections/gaugesJ. Fuel connections/gauges
K. Battery plug connection (if it’sK. Battery plug connection (if it’s
electric)electric)
INSPECTIONSINSPECTIONS (cont.)(cont.)

29. Checking the oilChecking the oil
Add or Low
fullfull
Operating rangeOperating range
From low to full couldFrom low to full could
be 1 Qt. to 1 gallonbe 1 Qt. to 1 gallon..
Put a little in and checkPut a little in and check
level. Keep doing that.level. Keep doing that.
DO NOT OVERFILLDO NOT OVERFILL
Be on a levelBe on a level
surface to checksurface to check
the oil. Like onthe oil. Like on
a concrete pad ora concrete pad or
shop floor.shop floor.

30. • Any maintenance problems should beAny maintenance problems should be
brought to the attention of supervision sobrought to the attention of supervision so
that appropriate repairs can be made.that appropriate repairs can be made.

31. INSPECTIONSINSPECTIONS (cont.)(cont.)
• Forklifts in an unsafeForklifts in an unsafe
conditioncondition should never beshould never be
used.used.

32. NATIONAL SAFETYNATIONAL SAFETY
COUNCIL SAYS . . .COUNCIL SAYS . . .
• The most serious defect isThe most serious defect is BRAKE
FAILURE..

33. DAMAGE TO FORKLIFTDAMAGE TO FORKLIFT
• If the forklift is damaged in any way orIf the forklift is damaged in any way or
develops any kind of mechanical problemdevelops any kind of mechanical problem
while being used it must be immediatelywhile being used it must be immediately
reported to your supervisor.reported to your supervisor.
• Do not park a defective forklift withoutDo not park a defective forklift without
tagging it out & telling your supervisor.tagging it out & telling your supervisor.

34. OSHA SAYS . . .OSHA SAYS . . .
• Only trained and/or qualified personsOnly trained and/or qualified persons
should make repairs to forklifts.should make repairs to forklifts.

35. Operating RulesOperating Rules

36. FOLLOWING ANOTHERFOLLOWING ANOTHER
TRUCKTRUCK
• When one forklift is following another, theWhen one forklift is following another, the
following forklift should maintain afollowing forklift should maintain a
distance of three (3) trucks behind thedistance of three (3) trucks behind the
first.first.

37. QUICK STOPSQUICK STOPS
• Although the forklifts can be stopped in aAlthough the forklifts can be stopped in a
short distance, the load cannot stop as fast.short distance, the load cannot stop as fast.
• A quick stop may cause the forklift toA quick stop may cause the forklift to
loose the load or tip forward.loose the load or tip forward.

38. USE OF HORNUSE OF HORN
• The horn should be used to warnThe horn should be used to warn
pedestrians that you are approachingpedestrians that you are approaching
• The horn should also be sounded uponThe horn should also be sounded upon
entering a building or rounding a blindentering a building or rounding a blind
cornercorner
• Sound the horn and look in direction ofSound the horn and look in direction of
travel BEFORE backingtravel BEFORE backing

39. • It is especially important to sound the horn whenIt is especially important to sound the horn when
entering or leaving buildings where employeesentering or leaving buildings where employees
may be walking across the path of the forklift.may be walking across the path of the forklift.
• Also, be especially careful when entering aAlso, be especially careful when entering a
building from outside as your eyes will not bebuilding from outside as your eyes will not be
adjusted to the lower light.adjusted to the lower light.
• Horns should never be used to startle fellowHorns should never be used to startle fellow
employees.employees.
USE OF HORN (cont.)USE OF HORN (cont.)

40. UNATTENDED FORKLIFTSUNATTENDED FORKLIFTS
• The definition of anThe definition of an
unattended forkliftunattended forklift
is:is:
– when you are notwhen you are not
within clear view of thewithin clear view of the
truck, ortruck, or
– when you are morewhen you are more
than twenty five feetthan twenty five feet
(25) feet away from it.(25) feet away from it.

41. UNATTENDED FORKLIFT (cont.)UNATTENDED FORKLIFT (cont.)
So. . .If the forklift is unattended, youSo. . .If the forklift is unattended, you
mustmust
• shut down the engineshut down the engine
• fully ground the forksfully ground the forks
• neutralized the controlsneutralized the controls
• set the emergency brake, andset the emergency brake, and
• not parked on an incline (unlessnot parked on an incline (unless
chocks are used)chocks are used)

42. UNATTENDED FORKLIFT (cont.)UNATTENDED FORKLIFT (cont.)
• If you get off of the forklift butIf you get off of the forklift but
do not leave it unattended thendo not leave it unattended then
you mustyou must
– Lower the forks to the ground,Lower the forks to the ground,
– Neutralize the controls andNeutralize the controls and
– Set the emergency brakeSet the emergency brake
– Chock wheels if on an inclineChock wheels if on an incline

43. UNDER NOUNDER NO
CIRCUMSTANCES. . .CIRCUMSTANCES. . .
• Should a forkliftShould a forklift
be allowed to liftbe allowed to lift
any more than itsany more than its
rated capacity.rated capacity.

44. STABILITY OF LOAD &STABILITY OF LOAD &
TRAVELINGTRAVELING
• Loads should be stable. RememberLoads should be stable. Remember
that shop floors have rough placesthat shop floors have rough places
and so does the yard.and so does the yard.
• Loads should be balanced, secureLoads should be balanced, secure
and stable so there is no possibilityand stable so there is no possibility
of loosing the load during transit.of loosing the load during transit.

45. TRAVELINGTRAVELING
• Keep the loadKeep the load
against theagainst the
backrest (mast)backrest (mast)
as much asas much as
possible.possible.

46. TRAVELINGTRAVELING (cont.)(cont.)
• 10% grade is when a slope changes 1010% grade is when a slope changes 10
feet in height in a 100 feet of distance.feet in height in a 100 feet of distance.
• When going up or down an incline ofWhen going up or down an incline of
10 percent grade or more while loaded,10 percent grade or more while loaded,
keep the load uphill.keep the load uphill.
• In other words, go up the grade inIn other words, go up the grade in
forward and come down the grade inforward and come down the grade in
reverse.reverse.

47. RAILROAD TRACKSRAILROAD TRACKS
• When crossing railroad tracks, the truckWhen crossing railroad tracks, the truck
should cross the tracks diagonally (at anshould cross the tracks diagonally (at an
angle).angle).
• No parking within 8 ft. of the center of theNo parking within 8 ft. of the center of the
RR tracksRR tracks

48. TRAVELINGTRAVELING (cont.)(cont.)
• Whether loaded or unloaded, do notWhether loaded or unloaded, do not
run over any avoidable objects suchrun over any avoidable objects such
as beam, pipe, loose items, etc. asas beam, pipe, loose items, etc. as
tire damage and possible tippingtire damage and possible tipping
may occur.may occur.
• Also, avoid any wet spots on shopAlso, avoid any wet spots on shop
floors as this will effect brakingfloors as this will effect braking
ability and steering control.ability and steering control.

49. MANEUVERINGMANEUVERING
• When unable toWhen unable to
see in front of yousee in front of you
because of a largebecause of a large
load, you shouldload, you should
drive backwardsdrive backwards
or have a spotter.or have a spotter.

50. PERSONNEL LIFTINGPERSONNEL LIFTING
• Employees should never be allowedEmployees should never be allowed
to be lifted on the forksto be lifted on the forks unless theunless the
proper personnel basket is usedproper personnel basket is used..
• Safety platform must be firmlySafety platform must be firmly
secured to the lifting carriage and/orsecured to the lifting carriage and/or
forks.forks.
• Means shall be provided wherebyMeans shall be provided whereby
personnel on the platform can shutpersonnel on the platform can shut
off power to the truck.off power to the truck.

51. RIDERSRIDERS
• Under no circumstancesUnder no circumstances
should anyone be on ashould anyone be on a
forklift except theforklift except the
operator (unless a safeoperator (unless a safe
place is provided)place is provided)
• This is the operator’sThis is the operator’s
responsibilityresponsibility

52. OVERHEAD CLEARANCEOVERHEAD CLEARANCE
• Always watch for overheadAlways watch for overhead
clearance such as piping,clearance such as piping,
overhead doors,overhead doors,
craneways, etc.craneways, etc.
• Never get any closer to anNever get any closer to an
electrical line than 20 feet.electrical line than 20 feet.

53. TRAVELINGTRAVELING
• Travel should be smooth,Travel should be smooth,
slow, cautious and theslow, cautious and the
operatoroperator must alwaysmust always
look in the direction oflook in the direction of
traveltravel beforebefore
beginning tobeginning to
movemove..

54. TRAVELING (cont.)TRAVELING (cont.)
• The mast should be tiltedThe mast should be tilted
slightly back, whenslightly back, when
possible, while travelingpossible, while traveling
with a loadwith a load..

55. TRAVELING (cont.)TRAVELING (cont.)
• Forklifts must neverForklifts must never
be driven up tobe driven up to
someone standing insomeone standing in
front of a bench orfront of a bench or
other fixed object.other fixed object.

56. OPERATINGOPERATING
• Arms and legs shouldArms and legs should
never be outside thenever be outside the
confines of theconfines of the
forklift cab orforklift cab or
operators position.operators position.

57. OPERATING (cont.)OPERATING (cont.)
• Never pass anotherNever pass another
forklift going in the sameforklift going in the same
direction while in thedirection while in the
shops.shops.
• Pedestrians always havePedestrians always have
the right of way.the right of way.

58. MANEUVERING & STACKINGMANEUVERING & STACKING
• Do not combineDo not combine
turning,turning,
raising/loweringraising/lowering
forks and depositingforks and depositing
load all at one time.load all at one time.
• The procedureThe procedure
should be as follows:should be as follows:

59. MANEUVERING &MANEUVERING &
STACKINGSTACKING (cont.)(cont.)
1. Drive up to the place1. Drive up to the place
you intend to deposityou intend to deposit
or pick up load andor pick up load and
stop.stop.
2. Raise or lower forks2. Raise or lower forks
and tilt forward orand tilt forward or
back to deposit or pickback to deposit or pick
up load.up load.

60. MANEUVERING &MANEUVERING &
STACKINGSTACKING (cont.)(cont.)
3. Creep forward and deposit3. Creep forward and deposit
or pick up load.or pick up load.
4. Adjust forks and tilt.4. Adjust forks and tilt.
5. Look to direction of travel.5. Look to direction of travel.
6. Slowly begin travel.6. Slowly begin travel.

61. DAMAGE REPORTINGDAMAGE REPORTING
• While handling material, report anyWhile handling material, report any
damage to the material immediatelydamage to the material immediately
to your supervisor.to your supervisor.
• The damaged material may takeThe damaged material may take
time to replace and the quicker thetime to replace and the quicker the
damage is reported, the quicker itdamage is reported, the quicker it
can be fixed or re-ordered.can be fixed or re-ordered.

62. DAMAGE REPORTING (cont.)DAMAGE REPORTING (cont.)
• Report any damage to propertyReport any damage to property
immediately. This includes damageimmediately. This includes damage
– To doors,To doors,
– Buildings,Buildings,
– Structures,Structures,
– The forktruck, orThe forktruck, or
– Other equipment, etc.Other equipment, etc.

63. HANDLING VESSELSHANDLING VESSELS
• Name plates on bottles & scrubbers - doName plates on bottles & scrubbers - do
not allow them to be damaged.not allow them to be damaged.
• Screwed fittings - do not allow the bottleScrewed fittings - do not allow the bottle
to rest on these fittings or let the bottleto rest on these fittings or let the bottle
roll over on these fittingsroll over on these fittings
• Use caution so that flange faces are notUse caution so that flange faces are not
damageddamaged
• To accomplish this, the bottles may haveTo accomplish this, the bottles may have
to be suspended under the forks usingto be suspended under the forks using
chokers rather than sitting on the forks.chokers rather than sitting on the forks.

64. • It is the operator’sIt is the operator’s
responsibility to figureresponsibility to figure
out how to avoidout how to avoid
damage to thesedamage to these
vessels or any othervessels or any other
load.load.
HANDLING VESSELS (cont.)HANDLING VESSELS (cont.)

65. REFUELINGREFUELING
• During refueling the engine must beDuring refueling the engine must be
shut down.shut down.
• Forklift must be parked away fromForklift must be parked away from
any hot work or heat producingany hot work or heat producing
operations.operations.
• No smoking.No smoking.
• If propane fuel is used, return emptyIf propane fuel is used, return empty
tank to the proper place.tank to the proper place.

66. PropanePropane
Relief valve
must be
pointed UP
Line up
holes with
peg

67. WHEN PARKINGWHEN PARKING
• When parking the forklift be sure itWhen parking the forklift be sure it
is not blockingis not blocking
– Aisles,Aisles,
– Fire extinguishers,Fire extinguishers,
– Electrical panels , orElectrical panels , or
– Exit doors.Exit doors.

68. WHEN PARKING (cont.)WHEN PARKING (cont.)
• Shut the engine down,Shut the engine down,
• Set the handbrake,Set the handbrake,
• Ground and levelGround and level
forks,forks,
• Neutralize controls,Neutralize controls,
andand
• Chock wheels if on anChock wheels if on an
incline.incline.

69. MOUNTING AND DISMOUNTINGMOUNTING AND DISMOUNTING
• Do not “jump” off the forkliftDo not “jump” off the forklift
• Use handrails and take your timeUse handrails and take your time
(maintain 3-point contact at all times)(maintain 3-point contact at all times)
• If the anti-skid surfaces get worn down -If the anti-skid surfaces get worn down -
anti-skid tape can be put on them.anti-skid tape can be put on them.

70. FINALLY . . .FINALLY . . .
• Take care of the machineTake care of the machine
• Don't overloadDon't overload
• Report damageReport damage
• Operate at a safe speedOperate at a safe speed
• Obey all the rulesObey all the rules

71. QUIZQUIZ