Lesson 01:

Introduction

1. Introduction: ● What is a Forklift Truck? ● Types of Forklift Trucks ● Uses for Forklift Trucks ● Safety Measures for Forklift ● Trucks Regulations for Forklift Trucks ● How Does a Forklift ● Work What Is the Purpose of a Forklift? 2. Examination.

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Lesson 02:

Types of Forklift Trucks

1. Truck Type Forklift: ● Articulated forklift trucks ● Industrial Counterbalance Forklifts ● Industrial Side Loader Forklifts ●Industrial Reach Forklift Trucks ●Turret Forklift ● Rough Terrain Forklifts ● Rotating or Roto Telehandler ● Straight Mast 2. Stand Up Forklifts: ● Order Picker Trucks ● Stand Up Trucks ● Double Deep Forklift ● Walkie Forklifts 3. Examination.

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Lesson 03:

Parts of a Forklifts

1. Parts of Forklift: ● Load back-rest: This part keeps the load from shifting backwards. ● Overhead guard: This section of the forklift protects operators from a load if it falls. ● Carriage: The carriage is the base of the forklift and is fixed on mast rails to easily move up and down. ● Forks: These are the prongs that carry loads. ● Mast: The mast raises and lowers the load. It also has interlocking rails that provide horizontal control. ● Counter weight: This weight is used to stabilize the forklift and keep it from tipping over. ● Power source: Forklifts can be powered by things like fuel cells, propane gas, gasoline, diesel engine or batteries. ● Truck frame: The frame is the base of the machine and all parts are attached to it. ● Tires: Forklifts can use pneumatic tires (normally used outdoors) or solid tires (sometimes called cushion tires) that are used both indoors and on hard, flat surfaces. 2. Parts of the Hydraulic: ● Lift handle: Operator pushes this to lift or lower the forklift’s load. This handle is connected to a pump found at the machine’s base. ● Pump: When activated, it pushes fluid through a tube leading to both hydraulic cylinders. ● Hydraulic cylinders: These are composed of a hollow tube that is shut on one end to trap fluids. A movable, lubricated piston is equipped on the other end. Here’s how the hydraulic system works: ■ Fluid enters the hydraulic cylinder through a special valve that allows it to enter without it escaping. Pressure increases as fluids increases in the cylinder. ■ Upward force is created when pressure is applied across the area of the piston head. ■ The piston moves up as a result of the force below it. This increases fluid and decreases pressure. ■ Physical equilibrium is achieved at this point when, at a given lift height, the fluids’ force is equal to the forklift load’s downward force. 3. Examination.

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Lesson 04:

Forklift Controls and Uses

1. Controls: Two Type Control is ● Steering Controls ● Lifting Controls: ■ Forward: Air is pumped into the chamber. The rise in pressure level pushes the piston head and results in the mast tilting away from the frame. ■ Back: Air is gently released from the chamber and air is pumped in the other pair of cylinders we mentioned earlier from the hydraulic system. The masts lean towards the vehicle when those pistons push that pair of cylinders forward. 2. Uses: Here are a few common ways forklifts are used: ● Construction Sites: Carry building material across long distances and rough terrain. ● Warehouses: Unload and load trucks to store goods in a warehouse. ● Recycling operations: Unload recycling materials and transport to their respective sorting areas. ● Dockyards: Load girth materials on and off ships and barges, especially when swift loading is needed ● Snow plows: Clear away snow when using a special attachment. 3. Examination.

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Lesson 05:

Forklift Safety

Causes of Forklift Accidents: ● Speeding ● Moving while the load is elevated ● Unaware pedestrians ● Loads that exceed the weight limit ● Other improper driving methods. Neglected Aspects of Forklift Accidents: ● Jumping out of the forklift ● Signage and markers ● Crowded pathway ● Inspection and maintenance of forklifts Forklift Safety: 1. Qualified operators only 2. Wear the correct clothing 3. Equipment inspection 4. Beginning work 5. The operating environment 6. Appropriate travel speed 7. Hazard avoidances 8. Safe operating distance 9. Load stability 10. Maintaining all-round clear visibility 11. Correct equipment uses 12. Restricted area 13. Driving on ramps 14. Secure the load 15. Do not exceed equipment capacity 16. Evenly distributed loads 17. Special loads 18. Observe operating environment changes 19. Refueling 20. Shift end 21. Install and Maintain Safety Guards 22. Do Not Modify Your Fork Truck 23. Install Gas Detectors 24. Install an Operator Restraint System 25. Separate Foot and Forklift Traffic. Warehouse Safety: ● Materials lifting ● Forklift and other vehicles ● Personal Protective Equipment (PPE) ● Fire hazards ● Hazardous chemicals and materials ● Slips and falls ● Pallets and racking.

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Lesson 06:

Forklift Capacity Plate

● What is a forklift data plate? ● What information is included on a forklift data plate: ● Forklift model number ● Serial number ● Mast type ● Fuel type ● Back tilt ● Attachments ● Front Tread ● Tire size ● Truck weight ● Forklift Diagram: ■ Horizontal load center ■ Vertical load center ■ Maximum fork height ■ Maximum offset distance for forks from the centerline. ● How is a forklift’s load capacity determined?

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Lesson 07:

Forklift Operational Inspection

Visual inspection: ● Floor – clear path of operation ● General condition and cleanliness ● Charged fire extinguisher ● Overhead – no obstructions ● Engine oil level ● Fuel level ● Radiator water level ● Forks – forks not bent; no cracks present ● Positioning latches in good working condition ● Carriage teeth not broken, chipped or worn ● Bolts, nuts, guards, chains, or hydraulic hose reels not damaged, missing or loose. ● Battery – fully charged and plug connections not loose ● Battery electrolyte levels in cells is adequate ● Hoses – held securely; not loose, crimped, worn or rubbing. ● Battery secured in place by hold downs or brackets ● Wheels and tyres – check for wear, damage, and air pressure ● Seatbelt and/or operator restraint device – belts and restraints work properly ● Chain anchor pins – not worn, loose or bent. ● Fluid leaks – no damp spots or drips. ● Overhead guard – no damaged areas. ● Horn – working and loud. Operational Inspection: ● Listen for any unusual sounds or noises ● Foot Brake – unit stops smoothly ● Lift Mechanism – operates smoothly all the way up and down ● Tilt Mechanism – moves smoothly ● Clutch and Gearshift – shifts smoothly ● Deadman Seat Brake – holds when operator rises from seat ● Parking Brake – holds against slight acceleration ● Steering – moves smoothly ● Dash Control Panel – all lights and gauges are operational ● Cylinders and Hoses – not leaking after above checks.

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Lesson 08:

Forklift Operations

1. Plan and prepare for work: ● Work requirements are identified and correctly interpreted ensuring quality requirements are met. ● Job instructions are read and clarified where needed. ● Work area is inspected and prepared as per job requirement. ● Types of forklift are identified and selected appropriate to job requirement. ● Appropriate personal protective equipment (PPE) is identified and selected. ● Tools and equipment are identified, checked for serviceability and selected. 2. Prepare for forklift operations: ● Access, interpret and apply forklift and load handling documentation to ensure compliance. ● Potential risks, hazards and environmental issues are identified and addressed, and implement control measures. ● Forklift attachments are identified and selected ensuring compliance with operating capacity. ● Roles and responsibilities of team are identified and employed prior to, during and after completion of forklift operations. 3. Operate forklift: ● Pre-start and start-up procedures are carried out. ● Forklift attachments are fitted, used and removed correctly. ● Maneuvering and positioning of forklift is performed smoothly. ● Load is secured, lifted, transferred and placed safely and securely. ● Monitors and alarms are checked during operation of forklift to ensure safe completion of task. ● Shutdown procedure is followed as per standard operating procedure. 4. Carry out forklift maintenance: ● Forklift is checked, and routine maintenance is performed, if required. ● Major faults are identified and reported for repair or replacement. ● Forklift and forklift attachments are cleaned as per standard operating procedure.

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Lesson 09:

Forklift Stability

Forklift Stability Essentials: ● The Stability Triangle ● Longitudinal Stability ● Lateral Stability ● Load Capacity ● Dynamic Stability ● The Operating Environment ● Forklift Tip Over Procedures ● Load with care ● Don’t overload ● Adjust to your load ● Lower your forks ● Check surface conditions ● Beware of slopes ● Corner slowly ● Drive smoothly ● Know your heights ● Wear a seatbelt ● Counterbalance forklifts ● “Stability triangle ● Dynamic effects on stability ● Centre of mass ● Dynamic forces, centre of mass and stability ● Tipover sideways versus tipover forwards ● Stability and raised loads ● Australian and international standards for forklift stability or safety ● Australian and international standards – forklift stability tests. ● Summary of Stability Issues and Means To Reduce Risk

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Lesson 10:

Load Handling

Load Handling: ● Safe handling preparation: ■ Off-center loads which may cause tip over or falling loads. ■ Overloading which may cause tip over or falling loads. ■ Damaged or loose loads. ● Approaching: ■ Approaching too fast. ■ Turning too rapidly. ● Mast position: ■ Tip overs and dropped loads while moving the mast. ■ Tilt the mast back and position the heaviest part of the load against the carriage. ■ Travel with the mast tilted back to keep the load stable. ● Fork position: ■ Tip over ■ Dropped load ■ Collision ■ Level the forks before inserting them into the pallet. ■ Slide the forks into the pallet until they are fully under the load. The forks should be at least two-thirds the length of the load ■ Tilt the mast back carefully to stabilize the load ■ Pick up an off-center load carefully. There is a greater danger of a tip over. ● Lifting the load: ■ Insufficient clearance ■ Falling loads ■ Stuck loads ■ Ensure that the load does not catch on any obstructions. ■ Slowly return the lift control lever to the neutral position. ● Lowering the load: ■ Falling loads. ■ Striking objects. ■ Ensure the load is secured before moving. ■ Carefully tilt the mast backward to stabilize the load. ■ Slowly move the truck to 20 to 30 cm (8 to 12 inches) away from the stack. ■ Stop the truck ■ Return the mast to the vertical position before lowering the load. ● High tiering: ■ Overloading ■ Tip over ■ Set the heaviest loads on the bottom tier. ■ Set the lightest loads on the top tier. ● Truck trailers and railroad cars: ■ Falling off loading dock. ■ Moving trucks or railroad cars during loading and unloading. ■ Slipping or inadequate dock boards.

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Exam

Final Exam

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