Download the forklift operator training manual - Sue Schauls

1 ForkliftHandbook,*Stts AUT0M oTl uE REc raa/qlrrq 4u torn of ive RecJclersForktift operator training HandbookTable Of ContentsIntroduction..\Vhat is a Forklifr? ..12a -f . I A/aurnortzect (JPerators..Differences Berween forklifts andAutos ..4 Stabiliry ..5 Pre-Inspection..gOperation ..9 PostOperation ..12 Fueling/Charging ..13 ForkliftQuiz ..15 EmployeeAcknowledgment ..19 forklift operator training HandbookIntroductionOperating a forklift requires skill, training , and experience. Although itmay seem as easy as driving a ca\ there are many factors that make drivinga forklift much more difficult. Learning how to operate a forklift safely canhelp to prevent accidental injuries and possible death. The goal of forkliftt" training is to help you achieve a work environment that is accidentfree and meets OSFIA handbook will help guide you through the steps of how ro operare aforklift safely. Topics you will learn about include:l) How to safely operate a ) Pre- and post-operation ) Inspection and maintenance of the properly operated forklift , along with carefully followed safetyprocedures, will go a long way towards reachjng the goal of a safe workingenvironment at all operator training HandbookWhat is a Forktift?

2 A forklift is one type of power industrial truck that comes in differentshapes, sizes and forms. A forklift can be called a pallet truck, rider truck,fork truck, or lift truck. Yet, the ultimate purpose of a forklift is thesarne - to safely allow one person to lift and move large heavy loads withlittle effiort. For the purposes of this training , a forklift is a small or largeindustrial truck with a power-operated pronged platform (commonlyknown as forks).LightsOverhead GuardSteering WheelHornHourSeatMeterForksBe[tLift ControlBrake PedalA forklift operator should be aware of the multiple parts on a forklift (seediagram above) in order to safely operate the forklift and be able to detectwhen an unsafe vehicle needs to be removed from service. Be sure tofarrriliarizr-- yourself with the. parts on the forklift used within your : The diagram above maf or may not represent the type of forkliftused in your company. Your instructor will be able to tell you which ryp"of forklift you will be trained ChainsBackrestCarriageForklift operator training HandbookWhy is safety important where forklifts are concerned?]

3 The Bureau of Labor statistics estimates that approximately 90,000 forkliftaccidents occur annually that result in employee injuries, lost time, or death.'The four most common forklift -related deaths involve forklift overturns,workers on foot being struck by forklifts , workers being crushed by aforklift, and drivers falling from forklifts . It is estimated that inadequatetraining, at least in part, causes 2o-25o/o of the accidents. So, during yourforklift safery training , always keep in mind that you are being trained forthe safety of not only yourself, but also others around you as OperatorsHow can I become a certified forklift operator ?Receiving your certification for a forklift is very similar to gaining a driver'slicense for an automobile. You will be trained under the direct supervisionof an experienced forklift operator and must successfully complete thefollowing three parts of training :. formal instruction such as a lecture, discussion, interactive computerlearning, videotape and/or written material.

4 Practical training that includes hands-on demonstrations by thetrainer and exercises by the trainee (on the rype of forklift you willuse for work); and. an evaluation of the effectiveness of the training by observing yourperformance while doing actual work using the you have been trained, you will then be re-evaluated at least onceevery three years. However, your supervisor rr'ay require you to gothrough refresher training ifi you have been involved in an accident ornear-miss accident; you have received an evaluation that reveals you arenot operating the truck safely; you are assigned to drive a different t)?eof truck; or a condition in workplace changes in a manner that couldaffect the safe operation of the operator training HandbookDifferences BetweenForklifts and a forklifr isdifferent than driving anautomobile in many exampl., in mostautos, the front wheelssteer the vehicle in thedirection you want roturn or travel. Ffowever,on a forklift , the rearwheels control the steering.

5 The rear end of the forklift swings in a circlearound the front wheels that supporr mosr of the load youte of this large turning circle, always check to make sure there is roomfor the rear end to swing because it can swing out further than you expectand possibly cause an accident..BrakingThere is also a difference between a forklift 's and an autot capabiliry tostop. Most autos have a front and rear brake system that allows the vehicleto stop quickly. A forklift , on the other hand, has rear steering that makesit difficult to stop a forklift quickly. fn an auto, the steering system worlstogether with the brakes to guide you to a smooth stop. But, the rear steeringon a forklift can make it difficult to swerve and react quickly. Therefore,remember to drive at a safe speed and be aware of your r IAuto1rr1& Forktift4 Forktift operator training HandbookWeight of a forklift versus an autoAlthough a forklift is smaller than a ca\a forklift rnay be two to three timesheaviel The average forklift can weighfrom 3,000 to 4,500 pounds.

6 In orderto balance heary loads and help preventthe forklift from tipping over, a largecounterweight is mounted on the rear ofthe counterr^reight is a paft of theforklift's structure and should never haveanything added to it in an attempt tobalance the load stabiliry is an important topic because the leading cause of deathand serious injury involving forklifts stems from overturns caused byforklift instabiliry. forklift stabiliry can be described by four elements: thefulcrum point, center of gravity, the stabiliry triangle and the load PointThe fulcrum point rnay soundcomplicated, but think of it this way:As children we all played on seesaws,which have a board that is balancedin the rniddle by a support support piece is what is calledthe fulcrLrm point. On a forklifr,the fulcrum point is the front fulcrum point serves as a supportLoadpiece to balance the load and illustration at the right displays this ^teightForklift operator training HandbookCenter of Gravity (CG)In addition ro balancing both endsof the forklifr, we musr also balancein all directions.

7 Balancing in alldirections is better known as the, center of graaity. The center ofgraviry is that point where atlparts of a load or truck arebalanced in all directions and willremain at rest. As a driver it isimportant to remember that anewcenter of graviry is creared whenyou're handling a load ("r opposedto an empqF load) one thatcombines both the load's and the truckt cenrer of of it likeriding a tricycle. If you peddle a tricycle around a corner and shift the centerof gravity forward over the narrowest part of the tricycle, you are likely toturn over. But, if you shift your weight on the rear and place the center ofgravity over the widest part of the triq,cle, you are less likely to tip ,ity TriangleThat brings us to the stability triangle,the triangle on wheels. Think of thestability triangle as three imaginarylines that are connected by the cenreraxle to the front wheels of the order ro maintain a stable forklift ,you must keep the cenrer of gravitywithin the stabiliry most stable areawhile handling aload is close ro the base of the the load you are carrying moves roofar forward from the forklift 's base, itwill more than likely tip & Load CG6 LoadLoadForkLift &Load CGForklift &Load CGror[tift ccUNSTABLE rorkiift ioSTABLESTABLEUNSTABLEF orklift operator training HandbookSome factors that could cause instability are.]

8 Load too Excessively tilting the load Operating on a Heavy Inappropriate use of forklift Off-center Ilneven Quick , your potential to turn over can be reduced if you follow a fewsafety rules:. Make sure the load is stable and safely arranged on the Do not tilt the forks forward except when picking up or depositinga Keep the load low just above the pavement with the forks tilted backwhen Enter tractor-trailers or elevators squarely when picking up ordepositing Drive at a slow enough speed to allow you to stop Drive slowly on wet or slippery Avoid driving on unstable surfaces or where there are loose objectson the CenterFinally, keep the load center in mind when tryrng to remain stable orachieve stabiliry. The load center of a forklift is simply the distance fromthe front face of the forks to the center of dre load. The most importantthing to remember is that the further you move from the load center whenhauling a load, then the lower capacity your truck will be able to with your instructor to determine the maximum capacity that yourcompany's forklift can handle.

9 This can be found on the data plate locatedon the front of the forklift .'7 forklift operator training HandbookPre-f nspectionIt is recommended that youconduct your dally pre-inspection with the help of apre-inspection form to ensurethat you do not overlook certainhazards. Your forklift should beinspected for defects every d^yprior to your shift, and afteryour shifr has been completed.*.7.!it!/,{ $. #iP,; #,TrucLt Vek bdia3 Forlclift inrpeios ru bc omplccd drilT rt thc bcgining of och fiift- If no preblm c 6und, plc r chc& (/) io thc Ol( b*lf rhc irrm ds mt p$t iup ioq, plu e chel in thc llIS llllll bor and deibc rhc preblo ln drc @mmcnts sioaPhcrdrad< Inrpp0eblr boiDrtt', , /o| , '.2 -l--l-,l4tclct*i6r':',;',rl' :: i: i :.::: ril r:i .llrE,:l:91.,,l; Jatbi',; i,,.:,iii,i:i:j:,,H*nit u#,,li: j,.,, r:ii ;,:ii1:l:::i:,:Hydnulic CrnrmL; ; :;. :. ::; | ) a+ .:' i+lilw4iqt*r 'r:: ':'..;i.:;i.!i::liii;::;,liijii';iti::i: :1:l::.:i :i11:"i'::::iii:l:: :: ::jiL i :iliiilir 1ili1:11.}

10 :::::i :::::a:t;:irjiii;,',*iii:i",f,!il:,; ;tll.::.:i:tii:j:::ISr<ingitilij ii n:..::,:: ,:..,:.. :'.i::r:iiii:Orhal,;liriiiti, :9il !a-r:l ..:;bJ'i;ir' 1: l .;'r;i- ll':"()il lEtti1iv6 1**:' rt :r :.',..,1, ;, .' :,; t,l:dieor Wzra lad,ta. t :a ti: Lyt:i::.:.:.ia:.::a. ij:ii:. :it !-:iriii[",[,''4:i:r'1li:::i:i!!:ng-\-ei l- ffise,twr'ffi -*GFEHhFDYou should conduct yorrr inspection as follows:. Look around the forklift completely for any signs of Inspect the general condition and cleanliness of the Check your oil, fuel and radiator level. (If the forklift is electric,check the electrolyte level, battery phg, and connections).. Look for evidence of any damage ( , missing or loose bolts, nuts,chains, etc.). Observe condition of wheels and Honk the horn to ensure it is working Make sure the forks are in working Determine whether the chain anchor pins are worn, loose, or Look for fluid leaks, damp spots, or Make sure hoses are held securely in If authorized, check the battery cables and water Look for objects on the floor or overhead that could lead toan use an unsaG forklift .]]