FORKLIFT
OPERATOR QUALIFICATION
PROGRAM
Objectives of this course
• To become qualified to operate a forklift
(aka forktruck or Powered Industrial Truck)
•
•
•
•
Learn the rules for safe operation
How to avoid forktruck accidents
How to prevent high maintenance cost
Verify your understand of what you learned
with a quiz
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Qualification Program
• This program is not designed to "teach"
employees how to operate a forklift.
• It is intended only to confirm the safety
aspects of forklift operation for those
people already familiar with its operation.
Who Can Use A Lift Truck?
“Only trained and authorized personnel shall
be permitted to operate forklifts.”
Training requirement
• Phase 1: Classroom instruction & quiz
• Phase 2: Observation of the trainee operating a
truck by a person experienced in forklift operation
Notes about Phase 2:
– training must not endanger the trainee or other
employees.
– the observation must be completed on each truck the
employee will be assigned to operate.
Refresher training is required when . . .
• The operator has been observed operating in an
unsafe manner
• The operator is involved in an incident or nearmiss
• The operator is assigned to operate a different type
truck
• A condition in the workplace changes in a manner
that could affect safe operation of the truck.
• At least every 3 years.
HIGH ACCIDENT &
MAINTENACE COSTS
Are usually results of :
• Safety rule violations
• Near misses
• Hot-Dogging
• Lack of inspections
General Requirements
• Modifications or additions to forklifts must
be approved, in writing, by the manufacturer
• Name plates must reflect all front-end
attachments
• Nameplates must be in place and legible
General Requirements (cont.)
• Truck shall not be used around flammable
vapors or hazardous concentrations of metal
dust unless they are designated as a DY, EE,
or EX
• Attention should be paid to carbon
monoxide (CO) levels in work areas where
truck are operating
Load Center
Load center
MAXIMUM LOAD
• There will be several weights stenciled on
the nameplate.
• The weights listed will be with the uprights
vertical and the center of gravity of the
load at various distances from the
backrest.
4350# with load center 24” from backrest
24
4350
Name Plate
Tire size
2490 cap when load center
is 20” from backrest
Capacity
2190 cap when load center
is 30” from backrest
Load Center
Tire press
Important!
The higher the lift,
the lower the capacity
Movement of the stability triangle
2. Truck is loaded or
stopped quickly
1. Truck
stopped, no load
Stability Triangle
3. Truck is loaded on
right side or turning left
5. Truck is loaded and
4. Truck is lifting a load with the
loaded on left mast titled back
side and/or
turning right
Key points about the stability triangle
• If you get outside the stability triangle, the truck
could turn over
• No quick stops or turns
• Keep load low
• Inch slowly when load is lifted for deposit
• Keep loads stable on forks so they don’t shift
• Creep when carrying containers of liquid
• Tilt back no more than necessary
SURVIVING A TIP-OVER
•
•
•
•
Don’t jump
Hold on to steering wheel tightly
Brace feet with wide stance
Lean away from the tip direction
REAR-END STEERING
• Due to rear-end steering,
operators must slow down
in order to watch the tail
swing and the tips of the
forks at the same time.
• You can’t do this if your
driving too fast.
What’s wrong in this picture?
Load is way
to high
Load height is
O.K. if stopped
to stack, right?
Stopped
too fast!
Maybe should
be driving
backwards
Driver not at the
controls
FORKS (CONT.)
• When a forklift is
not in use, the forks
must be grounded
and leveled.
yes
no
FORKS (CONT.)
• Under no circumstances
should anyone be allowed
under raised forks,
whether loaded or empty.
• This includes fingers &
toes.
ELEVATION OF FORKS
• When traveling on level surfaces the forks
should never be raised more than about 4”
from the floor or ground.
• When on unlevel surfaces, the forks
should not be raised any higher than
necessary to clear the ground.
TRUCK INSPECTIONS
• Forklifts shall be examined before being placed
in service
• Trucks must be inspected at the end of each
shift when used around-the-clock
• Trucks used intermittently must be inspected at
the beginning of each day that the truck is used
• Daily inspections shall be retained for 45 days
• Monthly inspections shall be retained for at
least 13 months.
INSPECTIONS (cont.)
The inspection must at least include the
following :
A. Leaks (water, fuel, hydraulic
fluid, etc.)
B. Tire damage and adequate
inflation
C. Faulty operation of controls
INSPECTIONS (cont.)
D. Brake condition (service and emergency
brakes)
E. Proper steering
F. Proper accessory operation (horn, lights,
ignition switch, etc.)
G. Proper operation of lift/tilt mechanisms
INSPECTIONS (cont.)
H. Defects in forks
I. Battery charging
J. Fuel connections/gauges
K. Battery plug connection (if it’s
electric)
Checking the oil
Operating range
Add or Low
Be on a level
surface to check
the oil. Like on
a concrete pad or
shop floor.
full
From low to full could
be 1 Qt. to 1 gallon.
Put a little in and check
level. Keep doing that.
DO NOT OVERFILL
• Any maintenance problems should be
brought to the attention of supervision so
that appropriate repairs can be made.
INSPECTIONS (cont.)
• Forklifts in an unsafe
condition should never be
used.
NATIONAL SAFETY
COUNCIL SAYS . . .
• The most serious defect is BRAKE
FAILURE.
DAMAGE TO FORKLIFT
• If the forklift is damaged in any way or
develops any kind of mechanical problem
while being used it must be immediately
reported to your supervisor.
• Do not park a defective forklift without
tagging it out & telling your supervisor.
OSHA SAYS . . .
• Only trained and/or qualified persons
should make repairs to forklifts.
Operating Rules
FOLLOWING ANOTHER
TRUCK
• When one forklift is following another, the
following forklift should maintain a
distance of three (3) trucks behind the
first.
QUICK STOPS
• Although the forklifts can be stopped in a
short distance, the load cannot stop as fast.
• A quick stop may cause the forklift to
loose the load or tip forward.
USE OF HORN
• The horn should be used to warn
pedestrians that you are approaching
• The horn should also be sounded upon
entering a building or rounding a blind
corner
• Sound the horn and look in direction of
travel BEFORE backing
USE OF HORN (cont.)
• It is especially important to sound the horn when
entering or leaving buildings where employees
may be walking across the path of the forklift.
• Also, be especially careful when entering a
building from outside as your eyes will not be
adjusted to the lower light.
• Horns should never be used to startle fellow
employees.
UNATTENDED FORKLIFTS
• The definition of an
unattended forklift
is:
– when you are not
within clear view of the
truck, or
– when you are more
than twenty five feet
(25) feet away from it.
UNATTENDED FORKLIFT (cont.)
So. . .If the forklift is unattended, you
must
• shut down the engine
• fully ground the forks
• neutralized the controls
• set the emergency brake, and
• not parked on an incline (unless
chocks are used)
UNATTENDED FORKLIFT (cont.)
• If you get off of the forklift but
do not leave it unattended then
you must
– Lower the forks to the ground,
– Neutralize the controls and
– Set the emergency brake
– Chock wheels if on an incline
UNDER NO
CIRCUMSTANCES. . .
• Should a forklift
be allowed to lift
any more than its
rated capacity.
STABILITY OF LOAD &
TRAVELING
• Loads should be stable. Remember
that shop floors have rough places
and so does the yard.
• Loads should be balanced, secure
and stable so there is no possibility
of loosing the load during transit.
TRAVELING
• Keep the load
against the
backrest (mast)
as much as
possible.
TRAVELING (cont.)
• 10% grade is when a slope changes 10
feet in height in a 100 feet of distance.
• When going up or down an incline of
10 percent grade or more while loaded,
keep the load uphill.
• In other words, go up the grade in
forward and come down the grade in
reverse.
RAILROAD TRACKS
• When crossing railroad tracks, the truck
should cross the tracks diagonally (at an
angle).
• No parking within 8 ft. of the center of the
RR tracks
TRAVELING (cont.)
• Whether loaded or unloaded, do not
run over any avoidable objects such
as beam, pipe, loose items, etc. as
tire damage and possible tipping
may occur.
• Also, avoid any wet spots on shop
floors as this will effect braking
ability and steering control.
MANEUVERING
• When unable to
see in front of you
because of a large
load, you should
drive backwards
or have a spotter.
PERSONNEL LIFTING
• Employees should never be allowed
to be lifted on the forks unless the
proper personnel basket is used.
• Safety platform must be firmly
secured to the lifting carriage and/or
forks.
• Means shall be provided whereby
personnel on the platform can shut
off power to the truck.
RIDERS
• Under no circumstances
should anyone be on a
forklift except the
operator (unless a safe
place is provided)
• This is the operator’s
responsibility
OVERHEAD CLEARANCE
• Always watch for overhead
clearance such as piping,
overhead doors,
craneways, etc.
• Never get any closer to an
electrical line than 20 feet.
TRAVELING
• Travel should be smooth,
slow, cautious and the
operator must always
look in the direction of
travel before
beginning to
move.
TRAVELING (cont.)
• The mast should be tilted
slightly back, when
possible, while traveling
with a load.
TRAVELING (cont.)
• Forklifts must never
be driven up to
someone standing in
front of a bench or
other fixed object.
OPERATING
• Arms and legs should
never be outside the
confines of the
forklift cab or
operators position.
OPERATING (cont.)
• Never pass another
forklift going in the same
direction while in the
shops.
• Pedestrians always have
the right of way.
MANEUVERING & STACKING
• Do not combine
turning,
raising/lowering
forks and depositing
load all at one time.
• The procedure
should be as follows:
MANEUVERING &
STACKING (cont.)
1. Drive up to the place
you intend to deposit or
pick up load and stop.
2. Raise or lower forks
and tilt forward or
back to deposit or pick
up load.
MANEUVERING &
STACKING (cont.)
3. Creep forward and deposit
or pick up load.
4. Adjust forks and tilt.
5. Look to direction of travel.
6. Slowly begin travel.
DAMAGE REPORTING
• While handling material, report any
damage to the material immediately
to your supervisor.
• The damaged material may take
time to replace and the quicker the
damage is reported, the quicker it
can be fixed or re-ordered.
DAMAGE REPORTING (cont.)
• Report any damage to property
immediately. This includes damage
–
–
–
–
–
To doors,
Buildings,
Structures,
The forktruck, or
Other equipment, etc.
HANDLING VESSELS
• Name plates on bottles & scrubbers - do
not allow them to be damaged.
• Screwed fittings - do not allow the bottle
to rest on these fittings or let the bottle
roll over on these fittings
• Use caution so that flange faces are not
damaged
• To accomplish this, the bottles may have
to be suspended under the forks using
chokers rather than sitting on the forks.
HANDLING VESSELS (cont.)
• It is the operator’s
responsibility to figure
out how to avoid
damage to these
vessels or any other
load.
REFUELING
• During refueling the engine must be
shut down.
• Forklift must be parked away from
any hot work or heat producing
operations.
• No smoking.
• If propane fuel is used, return empty
tank to the proper place.
Propane
Line up
holes with
peg
Relief valve
must be
pointed UP
WHEN PARKING
• When parking the forklift be sure it
is not blocking
–
–
–
–
Aisles,
Fire extinguishers,
Electrical panels , or
Exit doors.
WHEN PARKING (cont.)
• Shut the engine down,
• Set the handbrake,
• Ground and level
forks,
• Neutralize controls,
and
• Chock wheels if on an
incline.
MOUNTING AND DISMOUNTING
• Do not “jump” off the forklift
• Use handrails and take your time
(maintain 3-point contact at all times)
• If the anti-skid surfaces get worn down anti-skid tape can be put on them.
FINALLY . . .
•
•
•
•
•
Take care of the machine
Don't overload
Report damage
Operate at a safe speed
Obey all the rules
QUIZ