Operator Safety Awareness Training for
Forklift
❖ LEARNING OBJECTIVES
By the end of this training, participants will be able to:
Define a forklift and its types and components.
Identify common hazards associated with forklift operations.
Understand pre-use inspection requirements.
Describe safe operating practices and load handling techniques.
Recognize legal and regulatory compliance standards.
Understand site-specific and general traffic control measures.
Learn emergency procedures and incident response protocols.
Recognize the importance of proper maintenance and defect reporting.
❖ COURSE CONTENT
1. Introduction to Forklifts
A forklift is a powered industrial truck used to lift, carry, and stack materials. It is
commonly used in warehouses, factories, and construction sites.
Types of Forklifts:
Counterbalance (Electric or Diesel)
Reach Truck
Pallet Jack (Manual or Powered)
Rough Terrain Forklift
Side Loader
Main Components:
Mast
Carriage
Forks (Tynes)
Load Backrest
Overhead Guard
Counterweight
Power Source (Battery/Diesel/LPG)
Operator’s Cab/Seat
2. Forklift Hazards and Risks
Hazard Cause Control Measure
Overturning Uneven load, turning too fast Drive slowly, carry loads low
Secure and center load, tilt mast
Load Falling Unstable or unbalanced loads
backward
Limited visibility, lack of Use spotters, mirrors, marked
Pedestrian Collision
barriers walkways
Poor Visibility Blind corners, high stacks Use horns, spotters, install mirrors
Operating on Ramps Load facing downgrade/incline Load must always face uphill
Worn Perform daily inspection and
Mechanical Failure
brakes/steering/hydraulics maintenance
3. Pre-Operation Inspection
Daily Safety Checklist Includes:
Brakes and steering
Horn and lights
Tires and wheels
Forks (cracks, bends)
Hydraulic lines (leaks)
Seat belt
Battery level or fuel gauge
Load chart visibility
Warning decals/signage
Operator manual presence
Purpose:
To identify any potential safety issues before operating the equipment.
4. Safe Operating Procedures
Always wear a seatbelt and use 3-point contact when mounting/dismounting.
Drive at safe speed; avoid sudden stops/turns.
Forks must be lowered when the forklift is parked.
Never carry passengers unless seat is provided.
Never exceed the rated load capacity.
Keep forks tilted back and low during travel.
Observe height limits while entering/exiting buildings.
Sound horn at intersections and blind spots.
5. Load Handling and Stability
Center of Gravity:
Always keep the load’s center of gravity within the forklift’s stability triangle.
Load Positioning:
Stack loads evenly.
Don’t tilt mast forward while moving.
Avoid carrying damaged or loosely stacked items.
Use of Attachments:
Special attachments like clamps or rotators must match the forklift's rating and be
included in training.
6. Traffic Control & Pedestrian Safety
Mark forklift-only and pedestrian-only zones.
Use mirrors and warning beacons.
Maintain clear aisles and emergency exits.
Install speed limits and directional signage in work areas.
Never drive forklift with elevated forks.
7. Legal & Regulatory Requirements
UAE Standards (and International):
UAE Federal Law No. 8 (1980) – Labour Law
ISO 5057 – Forklift Safety Guidelines
OSHA 1910.178 – Powered Industrial Trucks
EN 3691 – Safety requirements for industrial trucks
Employer must ensure certified training and authorization
8. Emergency Situations
Common Emergencies:
Forklift tip-over
Fuel or battery fires
Collision or pedestrian injury
Load spillage
Response Actions:
Do not jump if the forklift tips—brace yourself and hold the steering.
Shut down power and evacuate the area if fuel leaks or fire occurs.
Report all incidents immediately to the supervisor.
9. Maintenance and Defect Reporting
Operators should report any malfunctions or safety issues immediately.
Never operate a defective forklift.
Maintenance should only be performed by authorized personnel.
Use inspection logs and checklists consistently.
MOCK TEST QUESTIONS
1. What is the main purpose of the counterweight in a forklift?
a) Increase speed
b) Improve steering
c) Balance the load
d) Protect the engine
2. Which of the following is a correct forklift safety rule?
a) Drive with forks raised for better clearance
b) Exceed the rated load if the load is balanced
c) Always wear a seatbelt while operating
d) Use forks to push other materials
3. When traveling with a load, the forks should be:
a) High and tilted forward
b) Raised to eye level
c) Low and tilted back
d) Extended fully forward
4. The stability triangle refers to:
a) Forklift's steering range
b) The balance between load and counterweight
c) Travel direction
d) Parking zones
5. Before using a forklift, the operator should:
a) Only check tire pressure
b) Ask a colleague to test it
c) Perform a full pre-use inspection
d) Start and drive immediately
6. What should be done if a forklift tips over?
a) Jump out of the forklift
b) Try to hold the load
c) Brace yourself and stay inside
d) Reverse quickly
7. Which of the following is considered an unsafe practice?
a) Sounding the horn at blind spots
b) Exceeding speed limits
c) Using marked pedestrian paths
d) Centering the load on the forks
8. Which item is NOT part of a daily inspection?
a) Horn
b) Mast
c) Forks
d) Radio channels
9. The load center is defined as:
a) Distance from the operator to load
b) Weight of the load
c) Horizontal distance from the face of forks to load center
d) Where the load touches the ground
10. Who is responsible for ensuring a forklift is in safe condition?
a) Security guard
b) Maintenance supervisor
c) Operator
d) Pedestrian
