In many workplaces, forklifts are the Number One tool for material handling. As useful as they are, they can be deadly if operated improperly. For this reason, OSHA has strict requirements that only authorized and trained persons may operate forklifts. In addition to operator training, other employees who work around forklifts should be trained to recognize the potential hazards. 

By the end of this session, students should understand:
• The causes and prevention of forklift accidents
• Safety rules and tips for operating forklifts safely
• The importance of proper maintenance
• Forklifts are not toys, and fooling around and carelessness are among the leading causes of forklift accidents.

• Initial Operator – 4 hours

1. Introduction
• Overview of the program 
• Goal of the program: to provide a training program based on the trainee's prior knowledge, the types of vehicles used in the workplace, and the hazards of the workplace. 
• Course will utilize group discussion and hands-on practice. Each operator must obtain the knowledge and skills needed to do their job correctly and safely. 

2. Types, Features, and Physics 
• Familiarize each operator with the basic types and functions of powered industrial trucks. 
• Develop an understanding of the information shown on a data plate. 
• Understand the critical truck measurements that affect safety. 
• Understand the forces that cause tip-overs, and the truck design considerations and safety ratings that help prevent them, including the "stability triangle." 

3. Inspecting the vehicle 
• Understand the purpose and importance of pre-operational checks. 
• Provide a basic understanding of areas covered during a pre-operational check. 
• Familiarize each operator with a checklist for pre-operational checks, and what to do if a problem is discovered. 

4. Driving the Truck 
• Understand the elements of safe movement of a powered industrial truck. 
• Understand the differences between an automobile and a powered industrial truck. 
• Recognize the safety hazards associated with operating a powered industrial truck. 

5. Load Handling 
• Understand the elements of load lifting safety. 
• Understand the safe operating procedures for raising and lowering loads in aisles. 

6. LPG for Lift Trucks 
• Discuss LPG and its properties. 
• Understand the elements and procedures of safely refueling internal combustion vehicles. 
• Describe tank components: service valve, surge valve, relief valve, etc. 
• Discuss related safety issues. 

7. Battery and Charging 
• Understand the elements and procedures of safely changing and charging batteries. 
• Discuss filling procedures and maintenance. 
• Discuss related safety issues. 

8. Safety Concerns 
• Review/reinforce potential of serious injury. 
• Review/reinforce safety procedures in the facility. 

9. Specific Truck and Workplace Training/Hands-On 
• Review features of specific PIT's to be operated. Main parts of a forklift include:
 Overhead guard – protects from falling objects and rollovers.
 Lights and horn.
 Mast-tilts loads up and down.
 Operator controls.
 Load backrest extension – keep load from falling backwards.
 Lift carriage – raises and lowers forks.
 Forks – pick up and hold load.
 Dataplate – lists maximum weight it can carry.
 Fuel source – gasoline, diesel, propane, or batteries.
• Review operating procedures of specific PIT's to be operated. 
• Review safety concerns of specific PIT's to be operated. 
• Review workplace conditions and safety concerns of areas where PIT's will be operated. 
• Learn/practice actual operation of specific PIT's to be operated and specific workplace conditions where PIT's will be operated. 
• Demonstrate proficiency performing the powered industrial truck operator duties specific to the trainee's position and workplace conditions. 

10. Quiz 

11. Wrap-Up
• Ask for final questions.
• Make-sure everyone signed in.

Designed by: Denis Kennedy 
Copyright 2011 A+ Safety Training 
All Rights Reserved