1. Forktruck Training 101 By Safety First

2. Course Information and Certification Upon completion of this course you will take a comprehensive and practical exam. You must receive a score of 80% or better on both exams to receive your certification. Upon completion of this course you will take a comprehensive and practical exam. You must receive a score of 80% or better on both exams to receive your certification. You will be given a certification card that must be carried with you while you are operating a forktruck. You will be given a certification card that must be carried with you while you are operating a forktruck.

3. Your certification is good for 2 years. You will be expected to take a refresher class every 2 years to become re-certified. Your certification is good for 2 years. You will be expected to take a refresher class every 2 years to become re-certified.

4. Introduction

6. Section 1: The Major Parts Of A Forktruck And Their Functions Physical Properties Physical Properties Name plates consist of: Name plates consist of: Make & model number Make & model number Class of truck Class of truck Gross vehicle weight Gross vehicle weight Maximum forktruck capacity Maximum forktruck capacity Load center rating Load center rating

7. Counterbalance Counterbalance A heavy weight built into the rear of your forktruck. A heavy weight built into the rear of your forktruck. Purpose is to offset the weight of a load carried on the forks. Purpose is to offset the weight of a load carried on the forks. If your load is higher than the capacity rating of your forktruck you MUST get a different forktruck with a higher capacity rating. If your load is higher than the capacity rating of your forktruck you MUST get a different forktruck with a higher capacity rating.

8. Overhead guard Overhead guard This is not a rollover cage. This is not a rollover cage. It’s purpose is not to provide you with shade or protect you from rollovers. It’s purpose is not to provide you with shade or protect you from rollovers. It’s only purpose is to protect you from falling objects. It’s only purpose is to protect you from falling objects. If you are working with loads that go above your head, you must use a truck with an overhead guard. If you are working with loads that go above your head, you must use a truck with an overhead guard.

9. Mast, forks, and backrest. Mast, forks, and backrest. The mast lowers and raises your forks. The mast lowers and raises your forks. The forks support the load you are carrying The forks support the load you are carrying The backrest connects the mast and forks The backrest connects the mast and forks

10. Forktruck attachments Forktruck attachments At times you may need a forktruck attachment. At times you may need a forktruck attachment. Never use custom-built attachments without the approval of the manufacturer of the forktruck. Never use custom-built attachments without the approval of the manufacturer of the forktruck. Use only attachments listed in your forktruck manual. Use only attachments listed in your forktruck manual.

11. Manual Manual Contains information on the layout and controls. Contains information on the layout and controls. You should always consult your forktruck’s manual prior to performing any forktruck operation. Remember not all forktrucks share the same controls or layout. You should always consult your forktruck’s manual prior to performing any forktruck operation. Remember not all forktrucks share the same controls or layout.

12. Section 2: Load Forktrucks use a three-point suspension to handle heavy loads. Forktrucks use a three-point suspension to handle heavy loads. This is formed by the three suspension points of the forktruck. It consists of: the two front tires, rear wheel axle and the pivot pin. This suspension (also known as the stability triangle) supports the weight of the forktruck. This is formed by the three suspension points of the forktruck. It consists of: the two front tires, rear wheel axle and the pivot pin. This suspension (also known as the stability triangle) supports the weight of the forktruck.

13. Actions that can affect the stability triangle are: Actions that can affect the stability triangle are: Sudden stopping Sudden stopping Turning at a high speed, too sharply, or on an incline Turning at a high speed, too sharply, or on an incline Moving with the forks raised Moving with the forks raised Lifting a heavy or overly large load Lifting a heavy or overly large load

14. Turning on an incline Turning on an incline The forktruck has rear-wheel steering. This causes the forktruck to swing widely. The forktruck has rear-wheel steering. This causes the forktruck to swing widely. If you turn on a incline your forktruck may tip over. If you turn on a incline your forktruck may tip over.

15. Section 3: Safe Lifting The safe lifting capacity of a forktruck is dependent on the load center. The safe lifting capacity of a forktruck is dependent on the load center. The perfect spot for arranging a load on the forks is between the load center and the backrest. The perfect spot for arranging a load on the forks is between the load center and the backrest. Your forktruck name plate will tell you the load center for the vehicle. Your forktruck name plate will tell you the load center for the vehicle.

16. Two things can affect the load center Two things can affect the load center If the load is to heavy it will upset the stability of the forktruck and may cause the lift to tip over. If the load is to heavy it will upset the stability of the forktruck and may cause the lift to tip over. It the load’s center of gravity is beyond the load center it will affect the safe lifting capacity of the forktruck. It the load’s center of gravity is beyond the load center it will affect the safe lifting capacity of the forktruck.

17. If the load center is not adhered to it will effect the weight the forktruck can safety lift. If the load center is not adhered to it will effect the weight the forktruck can safety lift. If a load is moved one foot from the rated load center it will reduce the forktruck’s safe load lifting capacity well over 1000 pounds. If a load is moved one foot from the rated load center it will reduce the forktruck’s safe load lifting capacity well over 1000 pounds.

18. Two rules of thumb when lifting are: Two rules of thumb when lifting are: Place the heaviest part of the load as close to the backrest as reasonably Place the heaviest part of the load as close to the backrest as reasonably When carrying or lifting loads, always tilt the mast back slightly. This will help keep the load closer to the forktruck and help the forktruck”s center of gravity. When carrying or lifting loads, always tilt the mast back slightly. This will help keep the load closer to the forktruck and help the forktruck”s center of gravity.

19. Section 4: Forktruck Inspection By law, you must inspect your forktruck. By law, you must inspect your forktruck. Inspections are to be performed daily or every 8 hours when the forktruck is used for different shifts. Inspections are to be performed daily or every 8 hours when the forktruck is used for different shifts. You need to use a checklist in accordance with the manufacturer’s recommendations. You need to use a checklist in accordance with the manufacturer’s recommendations. All inspections must be recorded. All inspections must be recorded.

20. Things to check are: Things to check are: Battery plug connection Battery plug connection Lights – head and tail Lights – head and tail Horn Horn Brakes – service and seat brake Brakes – service and seat brake Battery load test Battery load test Hour meter Hour meter Steering Steering Tires Tires Other conditions Other conditions

21. Major fluid leaks. Major fluid leaks. Forks and mast. Look for wear and tear on chains in the mast and fork ends. Forks and mast. Look for wear and tear on chains in the mast and fork ends.

22. Any time you have a problem with your forktruck notify your supervisor. Any time you have a problem with your forktruck notify your supervisor.

23. Section 5: Driving Rules You are to wear your seat belt whether the work you are performing is indoors or outdoors. You are to wear your seat belt whether the work you are performing is indoors or outdoors. Make sure you load is secure before moving. Make sure you load is secure before moving. If you can’t see around your load drive in reverse while looking in the direction of travel. If you can’t see around your load drive in reverse while looking in the direction of travel.

24. When driving up an incline, slowly drive forward. Have a coworker direct your path. When driving up an incline, slowly drive forward. Have a coworker direct your path. When crossing aisles or blind spots sound horn so coworkers in the area will know you are there. When crossing aisles or blind spots sound horn so coworkers in the area will know you are there. If you have to turn always go to the inside of the turn. This will allow room for tail swing. If you have to turn always go to the inside of the turn. This will allow room for tail swing.

25. By law, any pedestrian in your path have the right of way. It is your responsibility to watch out for them. It is not their duty to watch out for you. By law, any pedestrian in your path have the right of way. It is your responsibility to watch out for them. It is not their duty to watch out for you. Passengers are not allowed on the forktruck unless the forktruck was manufactured with a passenger seat. Passengers are not allowed on the forktruck unless the forktruck was manufactured with a passenger seat.

26. Safe Speed Safe Speed Safe speed is the rate of travel that will permit the truck to stop well within the clear distance ahead or to make a turn without overturning. Safe speed is the rate of travel that will permit the truck to stop well within the clear distance ahead or to make a turn without overturning. Remember wet or slippery floors require a slower-than ordinary speed. Remember wet or slippery floors require a slower-than ordinary speed.

27. Section 6: General Operating Practices Be aware of your surroundings. There may be fire sprinklers or low-hanging lighting that can be struck if your load is too high. Be aware of your surroundings. There may be fire sprinklers or low-hanging lighting that can be struck if your load is too high. Never place yourself between the forktruck and another object. Never place yourself between the forktruck and another object. If using a spotting for a job always have line of sight with them. If using a spotting for a job always have line of sight with them.

28. Never place any part of your body outside the operator’s compartment. Never place any part of your body outside the operator’s compartment. No one is to ever stand or walk under raised forks. No one is to ever stand or walk under raised forks. Never leave your forktruck unattended. The definition of unattended is: Never leave your forktruck unattended. The definition of unattended is: If the operator is either 25 feet or farther away If the operator is either 25 feet or farther away

29. If the driver is out of sight of the forktruck. If the driver is out of sight of the forktruck. If you must leave your forktruck; truck forks must be lowered to the ground and the parking brake set. If you must leave your forktruck; truck forks must be lowered to the ground and the parking brake set.

30. When you park the forktruck the following procedures are to be followed: When you park the forktruck the following procedures are to be followed: Bring forktruck to a complete stop. Bring forktruck to a complete stop. Apply the parking brake. Apply the parking brake. Put gear in neutral. Put gear in neutral. Lower forks completely to the ground. Lower forks completely to the ground. Turn off engine. Turn off engine.

31. Section 7: Pre-start A pre-start review is required before starting any job. A pre-start review is required before starting any job. This will consist of: This will consist of: Identify the load to be carried. Identify the load to be carried. Know the weight, the capacity of the forktruck, the load’s center of gravity and the surface you will be driving on. Know the weight, the capacity of the forktruck, the load’s center of gravity and the surface you will be driving on. Know your destination. Know your destination. Be aware of where you’re going and if the destination can handle your forktruck and the load you will be delivering. Be aware of where you’re going and if the destination can handle your forktruck and the load you will be delivering. Know what PPE is required for the job. Know what PPE is required for the job. If you are unloading the load find out if you need steel-toed shoes, hard hat and gloves. If you are unloading the load find out if you need steel-toed shoes, hard hat and gloves.

32. What is expected of you if you are in an accident. What is expected of you if you are in an accident. If an emergency situation dial 911. If an emergency situation dial 911. Call your supervisor immediately. Call your supervisor immediately. Preserve the scene. Preserve the scene.

33. References Lawrence Livermore National Laboratory ES&H Manual. Lawrence Livermore National Laboratory ES&H Manual. Hagan Philip E.; Montgomery John F; O’Reilly James T. 2001 “Accident Prevention Manual: 12 edition. Itasca, Illinois. Hagan Philip E.; Montgomery John F; O’Reilly James T. 2001 “Accident Prevention Manual: 12 edition. Itasca, Illinois. Sands Richard; Gould Bob. 2002 “Lift Truck Operator Training”. Lawrence Livermore National Laboratory Training Group. Sands Richard; Gould Bob. 2002 “Lift Truck Operator Training”. Lawrence Livermore National Laboratory Training Group.