Forklift Training
By Roger Jefferies
Forklift Training
By Roger Jefferies
Copyright Roger Jefferies 2011
Smashwords Edition
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The contents of this ebook may be printed and used in training programs by the purchaser of the ebook. It may be used in as many classes and provided to as many individuals as required to complete your training. This material is not intended to be shared with third parties or other businesses for their training programs.
Table of Contents
Chapter 1 - Difference between a car and a forklift
Chapter 2 - Forklift Load Attachments
Chapter 4 - Surface Conditions
Chapter 9 - Loading - Unloading
Chapter 13 - Written test - Answer Sheet
Chapter 14 - Hands On Training
Chapter 16 - Hands On Evaluation check List
Chapter17 - Basic Daily Checklist
Chapter 18 - Extensive Daily Checklist
Formal Training
(Powered Industrial Lift trucks)
Figure 1 - Photo created by Tynt22
Training Requirements
The Occupational Safety and Health Administration (OSHA) requires all forklift operates to be properly trained. This training must include a formal training segment, a hands on training segment as well as a hands on evaluation. This training must be administered by a person with knowledge and experience in the operation of forklifts.
This training will instruct trainees in the proper operations of forklifts. The training will also include site specific instruction dealing with the unique characteristics or requirements of the workplace in which the operator will be working. This may include ramps, inclines, uneven surfaces or chemical hazards which are present.
The trainee will be allowed to operate a forklift during the training process as long as the trainee has shown the ability to control the machine and basic knowledge of safety requirements. Trainee's will only be allowed to operate a forklift when such operation poses no risk to other workers, pedestrians or onlookers in the area. All forklift operators must be a minimum of eighteen (18) years of age. All trainees must be observed at all times by a qualified person(s).
All segments of the training process should be documented and remain on file for future reference and training requirements. Any operator who is involved in an accident or observed operating a forklift in an unsafe manner will be required to undergo refresher training. The performance of all operators will be reviewed and evaluated at a minimum of every three (3) years. If an operator receives a poor or unacceptable evaluation the operator will be required to undergo refresher training.
Chapter One
Difference Between an Automobile and a Forklift
A standard sit-down forklift with a lift capacity of 5,000 pounds can weigh over 9,000 pounds with no load. This is more than twice the weight of an average sedan. The weight of the forklift will have a direct effect on the operation of the vehicle in the areas of braking and center of gravity. Due to the weigh and sturdy construction of the forklift, collisions can cause extensive damage to buildings, product, or shelving.
A forklift steers with its rear wheels. This is far different from a standard automobile which steers with its front wheels. As a result, the forklift has a wide rear-end swing which must be accounted for. The rear-end swing can cause severe damage to buildings, products and shelving. Rear-end swing is also a leading cause of pedestrian injuries. Pedestrians may become pinned between the forklift and another object when the machine makes a turn. This is often caused by pedestrians who are unfamiliar with forklift operation or operators who are unaware of their surroundings. Forklift operators must always be aware of any pedestrians walking or working near the forklift. Pedestrians always have the right-of-way.
Forklifts are often operated in very close confines. It is not uncommon for a forklift to have only inches of clearance on both sides of the machine. These conditions require the undivided attention of the forklift operator.
The standard forklift will have a much higher center of gravity (COG) than the standard automobile. This condition is further exaggerated when the machine is carrying a load, or maneuvering with the load raised. Forklifts have a tighter turning radius than an automobile but the turns must be made at lower speeds to avoid tip-over accidents, which are a leading cause of operator fatalities.
Truck Controls and Instrumentation
The forklift steering is controlled by a standard steering wheel. To turn right the operator will steer to the right. To turn left, the operator will steer to the left. The pivot point for the steering is the front axle.
The standard forklift will have three (3) foot control pedals. The pedal on the far right will be the accelerator. The speed of the forklift is controlled by depressing or releasing the accelerator pedal. The other two pedals are both brake pedals. Under normal operation the center brake pedal is the primary brake pedal. At times it will be necessary to apply pressure to the accelerator while also depressing the brake pedal. When this is the case, the left brake pedal will be used in conjunction with the accelerator pedal.
At times it will be necessary to increase the engine above an idle in order to raise a load. This can be done while the forklift is in gear. Depress the brake pedal and press down on the accelerator. Slowly release the brake pedal to allow the machine to inch forward as the load is simultaneously raised to the required height.
The emergency brake for the forklift will be located either on the dash of the forklift, or will be a smaller pedal on the floorboard of the machine. The emergency, or parking brake, must be disengaged when the machine is in operation. When the machine is parked or otherwise removed from service the emergency/parking brake must be engaged.
There will be a lever located on the left side of the steering column. This is the directional control. In order to move forward the lever must be pushed up/forward. To move the forklift in reverse pull the lever fully backward/down. The center position is neutral. When the machine is parked or taken out of service the directional control must be in the neutral position.
The three levers on the right side of the steering column control the mast functions.