Professional Documents
Culture Documents
Insurers Fund
Course Outline
I.
II.
III.
IV.
V.
VI.
Introduction
Lift Truck Basics
Fuels and Batteries
Emergency Situations
Fundamentals of Operation
Driving Test
I. Introduction
Recognition of emphasized
messages:
NOTE
This message is used when special information,
instructions, or identification is required relating to
procedures, equipment, tools, pressures,
capacities, and other special data.
IMPORTANT
This message is used when special precautions
should be taken to ensure a correct action or to
avoid damage to, or malfunction of, the truck or a
component.
CAUTION
This message is for proper precautions which, if
not followed, can result in personal injury.
WARNING
This message is used when a hazard exists
which can result in injury or death if proper
precautions are not taken.
DANGER
This message is used when an extreme hazard
exists which will result in death or serious injury if
proper precautions are not taken immediately.
Forklift Types
Narrow Aisle
Picker
Electric Standup
Forklift Types
Powered Pallet Truck
Upright
Lift Cylinder
Fuel Tank
Backrest
Counterweight
Tilt Cylinder
Carriage
Steer Axle and
Wheels
Data Plate
The data plate must be
in legible condition
A data plate provides
the following
information:
Maximum lift height
Attachment capacities
Maximum weight
capacities
Estimated lbs
Truck Weight
8,000 lbs
Capacity
4,000 lbs
Operator
175 lbs
Total
12,175 lbs
Load Center
The load center rating of a fork truck is the
maximum distance from the face of the forks to
the center of gravity of a capacity load.
The data plate will have this information.
Standard forks measure 24 at the load center.
For every inch beyond the rated load center that
the load is placed, approximately 100 lbs. of
capacity is lost.
Load Center
24
Stability
Even though a forklift has four wheels, it is
only supported at three points.
The steering axle of most four-wheel lift
trucks is attached by means of a pivot
point in the center of the axle.
Center of Gravity
The black spot in the triangle below represents the
Center of Gravity.
The Center of Gravity (CG) shifts according to the
movements of the truck.
If the CG moves outside the triangle the truck will
overturn.
Center of Gravity
Figure 1 shows
the CG shift when
the truck is loaded
and braking.
Figure 2 shows
the CG shift when
the truck is
uneven or turning
with excessive
speed.
Lift Height
Center of Gravity
Zone
3
Zone
2
Zone
1
Stability
As the CG gets
higher, the
stability of the lift
truck gets
smaller.
Loads must be
kept as low as
possible at all
times.
Operators Manual
Includes safe operating procedures and capacities
Diesel
Has higher ignition point than gas
Colorless
Slight odor, harder to detect than gas
Batteries
A lead-acid battery is a portable power
source for supplying direct current
electricity.
The most common voltages include 12,
24, 36, and 48 volts.
Discharging a battery below 80% of its
total capacity can result in shortened
battery and truck component life.
Battery Hazards
Sulfuric Acid Small amounts can cause severe
contact burns to the skin.
Gasses Batteries produce hydrogen and
oxygen mixture continuously. Keep all ignition
sources away.
Electricity Batteries are capable of producing
very high discharge rates. Avoid direct shorting
situations.
Battery Weight Use care when handling,
charging, and using batteries in the truck.
Battery Chargers
Two types:
Single Phase charger has two wires and a ground
with one transformer and two fuses.
Three Phase charger has three wires and a ground in
the power supply cable. It has three transformers and
three fuses.
Battery Charging
Battery recharging requires a special service
area in accordance with OSHA section (g)(1).
The area must be:
Well ventilated
Truck off, set parking brake
Jewelry is prohibited
Personal protective equipment should include safety
glasses, head protection, aprons, and gloves
All battery cables should be disconnected before
charger hook-up
Handling must be done according to manufacturers
recommendations
Battery Charging
Vent caps must be left on during charging.
If the battery is charged while still in the truck, the
compartment must be left open.
The charger should be turned off before it is
connected to the battery then turned on to begin the
charging cycle.
Color coded connectors help prevent connecting a
battery of the wrong voltage to the wrong charger or
truck.
Chargers should be properly set to avoid over or
under charging.
The charger should be turned off before disconnecting
from the battery.
Handling an Emergency
The three Cs, Check, Call, Care help us
remember what to do in an emergency situation.
Check check the area for your own safety first,
then the victim's
Call for help, 911 or whom ever is in the
immediate area that can provide assistance
Care - administer care to the victim, this may be
first aid or at least stabilization
V. Fundamentals of Operation
Personnel Elevators
Lift trucks are not designed to lift people.
There are machines designed for this
purpose;
Scissor lifts
Order Pickers (platform lift)
Elevated work platforms
Personnel Elevators
Must be designed by a professional
engineer
Must be designed to work with a specific
lift
Occupants must wear a harness and
lanyard
Operators must man controls at all times
Handling Loads
Always balance and secure the load.
Never pick loads that are too heavy.
Be aware of your clearances at all times.
Check for overhead obstructions or power
lines.
Center the load. Forks must be at least
2/3 the length of the load.
Handling Loads
2/ 3
Le n g
th
Handling Loads
When picking up a load, place the forks
under the load as far as possible.
Tilt the mast back slightly for stabilization.
Keep the load low. The forks should never
be more than 6 to 8 inches from the
ground.
Stacking
Square the truck to the rack/bin
and come to a complete stop
Elevate the load to the proper
height and Inch the truck in
Tilt the load forward for
placement.
Lower the forks to take
pressure off the pallet.
Back the truck up till the forks
clear and lower them before
traveling.
Use the same procedure in
reverse when picking up a load
from a stack.
Traveling
Understand the traffic
laws of your environment
Familiarize yourself with
the work area.
- Visibility
- Travel surface
Traveling
Grades, Ramps, and
Inclines
Travel must be straight up
and straight down. Never
turn on ramps, slopes, or
inclines.
With a load, travel up or
down with the load pointing
upgrade.
Without a load, travel up or
down with the forks
pointing downgrade.
The load should be tilted
back and raised only as
high as necessary to clear
the surface.
Traveling
Dock Operations
Before entering a tractor trailer make certain the
wheels are chocked.
Check the trailer jacks. Make sure they are fully
lowered and secured.
Inspect the floor of the trailer prior to driving on it.
Check the dock boards between the trailer and the
dock. Always travel slowly over dock boards.
Stay away from the edge of the dock.
Use lights to improve visibility while working in trailers.
Hands-On Section
Pre-operation Inspection
Familiarization with operating controls and
gauges
Driving exercises
Figure 8 Test
Reverse Mobility
Lifting and Carrying
Pre-Operational Checklist
Item
Ok
repair
Item
Tires, Axles
Overhead Guard/ROPS
Lights, Bodywork
Fuel Level
All Brakes
Steering
Ok
repair