TUV-TR-007 Rough Terrain Forklift Operation Training Course.ppt

rough terrain terrain

1. TELEHANDLER FORKLIFT (ROUGH TERRAIN)
SAFE OPERATION TRAINING COURSE
Slide 1

2. Slide 2
TRAINING OBJECTIVES
 KNOWING THE EQUIPMENT
 RELATIVE STANDARDS
 TYPES OF FORKLIFTS
 PARTS OF TELEHANDLER
 OPERATING THE TELEHANDLER
1. PRE-OPERATION
2. TRAVELING & MANEUVERING
3. LOAD HANDLING
 THE WORKPLACE

3. Slide 3
DEFINITIONS:
Powered Industrial Truck
- A mobile, power-propelled truck used to carry, push, pull, lift, stack or tier
materials. [American Society of Mechanical Engineers (ASME) definition]. Excluded are
vehicles used for earth moving and over-the-road hauling.
- Commonly known as forklifts, pallet trucks, rider trucks, fork trucks, or lift trucks.
- Can be powered through electric or combustion engines.
Forklift
A forklift (also called a lift truck, a high/low, a stacker-truck, trailer loader, side
loader or a fork hoist) is a powered industrial truck used to lift and transport
materials.
Telehandler
A telescopic handler, or telehandler, is a variable-reach forklift with the increased
versatility of a single telescopic boom that can extend forwards and upwards from
the vehicle. On the end of the boom the operator can fit one of several
attachments, such as a bucket, pallet forks, muck grab, or lift table.

4. Slide 4
APPLICABLE STANDARDS
OSHA & ANSI
•OSHA - powered industrial trucks
–Regulation 1910.178
–Regulation 1926.602
•ANSI - powered industrial trucks
–Standard B56.1
–Standard B56.6
To keep us alive!To keep us alive!

5. Slide 5
CLASSES OF POWERED INDUSTRIAL TRUCKS*
The Industrial Truck Association has placed powered industrial trucks
into 7 classes:
Class I - Electric motor rider trucks
Class II - Electric motor narrow aisle trucks
Class III - Electric motor hand trucks or hand/rider trucks
Class IV - Internal combustion engine trucks (solid/cushion tires
Class V - Internal combustion engine trucks (pneumatic tires)
Class VI - Electric and internal combustion engine tractors
Class VII - Rough terrain forklift trucks
* Note that this classification refers to commonly-used vehicles and
does not include all powered industrial trucks covered by the OSHA
standard.

6. Slide 6
TYPES OF ROUGH TERRAIN FORKLIFT TRUCKS
Modified pivot
Truck mount
Telescopic Boom
(Telehandler)
 Vertical lift mast

7. Slide 7
VERTICAL MAST FORKLIFT
Moves materials over rough terrain
Lifts materials vertically only
Mast tilts forward and backward
Fork options - side shift & rotate

8. Slide 8
MODIFIED PIVOT FORKLIFT
Moves Materials Over Rough Terrain
Lifts Materials Vertically
Limited Horizontal Reach
Many Possible Attachments

9. Slide 9
TRUCK MOUNTED FORKLIFT
Moves Materials Over Rough Terrain
Lifts Materials Vertically
Limited Horizontal Reach
Attaches to Vehicle for Transport

10. Slide 10
TELESCOPIC BOOM (TELEHANDLER) FORKLIFTS
Moves materials over
rough terrain
Lifts materials vertically
and horizontally.
Can reach over obstacles
Boom extend/retract
Fork options - side shift,
tilt & rotate
Large selection of
attachments

11. Slide 11
TELEHANDLER COMPARED TO VERTICAL MAST FORKLIFT
The Boom
Frame Tilt
Steering
The Carriage
Load Capacity
Operation

12. Slide 12
COMPARISON BETWEEN FORKLIFT & AUTOMATIC CAR
SIMILARITIES
Tires Brakes
Engine powered Control systems
Mirrors / Horn Blind spots
Travels Steering
Seat belt required
FORKLIFT AUTOMATIC CAR

13. Slide 13
COMPARISON BETWEEN FORKLIFT & AUTOMATIC CAR
DIFFERENCES
Weight Stopping Distance
Center of Gravity Steering Modes
No Suspension Stability
No Passengers
Seat belt required
FORKLIFT AUTOMATIC CAR

14. Slide 14
COUNTERBALANCED VS. NON-COUNTERBALANCED FORKLIFTS
COUNTERBALANCED NON-COUNTERBALANCED

15. Slide 15
COMPONENT LOCATIONS
PARTS
1.Mast and Carriage
2.Forks
3.Attachments
4.Nameplate
5.Danger, Warning & Ca
ution Labels
    
6.Controls
7.Instruments
8.Battery
9.Overhead Guard
10.Tires
11.Other Safety & Warnin
g Devices

16. Slide 16
COMPONENT LOCATIONS (cont.)
Mechanical Tow HitchEngine Cover Hydraulic Tow Hitch

17. Slide 17
MAST AND CARRIAGE
The mast is the vertical assembly that does the work of raising, lowering, and tilting the
load. The mast supports the carriage that allows its vertical movement with the hydraulic lift.
The
carriage is made of flat metal plates that move along the mast by chains or are directly attached
to the hydraulic cylinder. The hydraulic lift cylinder supplies the power to lift the load.
MAST TYPES:
1.SIMPLEX: The features of a simplex mast are:
Single stage mast.
Limited Free Lift (4-6") Free lift is the distance the forks go up before the mast is
extended. Recommended in loading and unloading trucks and in areas where overhead
clearance is a problem.
2.DUPLEX: The features of a duplex mast are:
Two stage mast.
Has greater Free Lift (50-60") than the simplex mast.
Can load and unload higher-tiered stacks than simplex.
3.TRIPLEX: The features of a triplex mast are:
Three stage mast.
Has same Free Lift (50-60") as duplex mast but extends further.
Can load and unload higher-tiered stacks than simplex or duplex.
4.QUAD: The features of a quad mast are:
Four stage mast.
Has same Free Lift (50-60") as duplex or triplex mast but extends further.
Can load and unload higher-tiered stocks than the duplex or triplex, but
requires precautions at its highest lifting heights.

18. Slide 18
MAST AND CARRIAGE
VISIBILITY
Mast configuration can affect the operator's visibility. Newer mast
designs, such as those that use two side cylinders, can provide
substantially improved visibility compared with some older mast
designs that have a single central cylinder.
The operator should travel with the load trailing and/or use a spotter
whenever necessary to achieve adequate visibility.
Mast with central cylinder
obscuring visibility.
High visibility mast with
hydraulic cylinders on the sides.

19. Slide 19
FORKS – POTENTIAL HAZARDS
A fork that shows any of the following defects shall be withdrawn from
service and discarded or properly repaired:
 Surface cracks.
 Blade or shank are not straight.
 Fork angle from blade to shank is not straight.
 Difference in height of fork tips.
 Positioning lock not in working order.
 Fork blade or shank wear.
 Fork hooks wear.
 Fork marking not legible.
OSHA Requirements and Recommended Practices:
 Do not operate the forklift if the forks show any of the defects listed above. 
 Always inspect forks during the pre-operation inspection. Repair or replace
the forks if they are not in good working order. Replacement parts shall be
equivalent as to safety with those used in the original design.
 Do not operate a forklift from which the positioning lock has been removed
or is inoperable. As the forklift travels, the positioning lock holds the forks in
position and prevents sliding of the forks and loss of the load.
Damaged Fork

20. Slide 20
ATTACHMENTS
Standard Carriage
Swing Carriage
Fork Mounted
Work Platform
Side Tilt
Carriage
Truss Boom
Sheet Material
Adapter
Lifting Hook
Material Buckets Grapple Bucket
Mast
Cubing Forks
Side Shift
Carriage
Bale Clamp
Round Bale Tine
Universal Skid
Steer Adapter
Powered industrial trucks often use various attachments in place of traditional forks.
These attachments increase the versatility of the truck, but can present important
safety considerations, including stability, capacity, and visibility.
Some common attachments are: (Source: www.jlg.com/telehandler/attachments)

21. Slide 21
ATTACHMENTS
Potential Hazards:
 Overloading.
 Tip over and falling loads.
OSHA Requirements:
Train operators in the fork and attachment adaptation, operation, and use limitations.  
Retrain an operator if a new attachment is added to the forklift.
Do not exceed the rated capacity of the forklift/attachment combination.
Know the mechanical limitations of your forklift.
Change capacity, operation, and maintenance instruction plates, tags,
or decals when a forklift truck is equipped with an attachment.
Treat an unloaded forklift with an attachment as partially loaded.
Include attachments in a scheduled maintenance and inspection program.
1.Examine load-bearing components for deformation.
2.Examine load-bearing welds for cracks.
3.Inspect mechanical and hydraulic components and maintain in accordance with the
manufacturer’s instructions.
If the truck is equipped with front-end attachments other than factory installed
attachments, request the truck be marked to identify the attachments and show the
approximate weight of the truck and attachment combination at maximum elevation
with load laterally centered.
Modifications or additions that affect capacity or safe operation shall not be performed
without prior written approval from the manufacturer.

22. Slide 22
NAME PLATE
The nameplate (also called the data plate) provides important
information for the forklift operator, including the fuel type,
forklift weight, and capacity. Operators should read the nameplate
to know the forklift’s capabilities and limitations.
Each operator is required to be aware of the truck specifications on
the nameplate and what they mean. If there is a special
attachment, it must be listed on the nameplate.

23. Slide 23
CAPACITY
The capacity is the manufacturer’s guideline for how much weight a
forklift can safety lift. Exceeding the capacity of a forklift presents serious
hazards, including tip over.
If the load has a different load center or it is irregular, such as a series of
boxes of varying weights, then the capacity must be recalculated.
OSHA Requirements and Recommended Practices:
 Train employees to properly read the nameplate and to understand what
the information means.
 Check the nameplate for maximum capacity and maximum height.
 Do not exceed the capacity of the truck.
 Understand that the addition of an attachment generally lowers
the capacity of a forklift.
 Understand that the size, position and weight distribution of the load also
affects the capacity. Capacity assumes the center of gravity of the load is at
the load center shown on the label. If this is not the case, the load may
exceed the forklift's capacity.

24. Slide 24
DANGER, WARNING AND CAUTION LABELS
In addition to the nameplate, forklifts may have other warning labels or decals
that provide safety information to operators. Safety labels should be clearly
visible to the operator and must be replaced if missing, damaged, or illegible.
Under one classification system, there are three types of warning labels or
decals:
DANGER means if the danger is not avoided, it will cause
death or serious injury.
 
WARNING means if the warning is not heeded, it can cause
death or serious injury.
 
CAUTION means if the precaution is not taken, it may cause
minor or moderate injury.

25. Slide 25
DANGER, WARNING AND CAUTION LABELS LOCATIONS (SAMPLE)

26. Slide 26
DANGER, WARNING AND CAUTION LABELS SAMPLES

27. Slide 27
CONTROLS
Location
Function
Method of Operation
Identification of Symbols

28. Slide 28
CONTROLS
Before operating a forklift, read and study the operator's manual discussion
on controls.
Locate each control and understand how to use each one.
Forward/Reverse Directional Controls
The directional control allows the operator to move the forklift forwards or
backwards. Directional controls can be column mounted (mounted on the steering
column) or foot operated (controlled by shifting the accelerator pedal side to side).
Hydraulic Lift Controls
Forklifts have hydraulic lift controls to raise and lower the forks and to tilt the
forks. Visually inspect the hydraulic controls before each use and test that they are
working properly.  
Pedals
Forklifts have accelerator and brake pedals that operate similarly to these pedals
in other vehicles. Some forklifts also have a clutch, which allows shifting into
higher forward gears. The inching pedal gives the operator more control of the
forklift in tight places.
Parking Brake
Forklifts are equipped with a parking brake. Be sure to set the parking brake when
leaving a forklift and block the wheels if the forklift is parked
on an incline.  

29. Forklifts have a variety of instruments on the
dashboard. Read your operator’s manual and
become familiar with each of the warning lights and
gauges on the dashboard. Never operate a forklift if
a warning light or gauge signals an unsafe
condition.
Instrument Panel
Oil Pressure Gauge
Temperature Gauge/Light
Transmission Temperature
Fuel Gauge
Hour Meter
Battery Discharge Indicator
Slide 29
INSTRUMENTS
Dashboard showing gauges on a forklift. These common forklift gauges show
normal operating condition.
Typical warning gauges.
Electronic engine oil gauge,
warning indicators.
Battery Low

30. Slide 30
INSTRUMENTS
INSTRUMENT PANEL
Read your operator's manual and become familiar
with each of the warning lights and gauges on the
dashboard. Know what each one indicates.
Potential Hazards:
Mechanical breakdown
Forklift malfunction
Requirements and Recommended Practices:
Turn on the forklift and check all the warning
indicators on your dashboard.
Never operate a forklift with a warning light or
gauge signaling an unsafe condition.
Do not attempt a repair unless authorized to
do so.
Report any abnormality to your supervisor.
These common forklift gauges show
normal operating condition.

31. Slide 31
INSTRUMENTS
OIL PRESSURE GAUGE
The oil pressure gauge indicates the oil
pressure inside the engine. An oil pressure
warning light may also be present.
Requirements and Recommended
Practices:
 Do not operate the forklift if the light
comes on or the gauge indicates oil
pressure problems.
 Check for leaks. Clean up any spills or
mark the hazard area until it can be
cleaned.
Notify your supervisor or maintenance
personnel.
 Only trained and authorized personnel
may service a forklift.
Typical warning gauges.
Electronic engine oil gauge,
warning indicators.

32. Slide 32
INSTRUMENTS
TEMPERATURE GAUGE/LIGHT
The engine temperature gauge is similar to the engine
temperature gauge found on a car or truck. Engine
temperature may be indicated by "C" for cold or green
indicating safe operating temperature, while a hot,
overheating engine may be indicated by an "H" for hot
or red.
Refer to your owner's manual for the appearance and
significance of your engine temperature gauge.
Requirements and Recommended Practices:
 Do not operate a forklift if the light comes on or the gauge indicates an
overheated engine.
 Check for leaks. Clean up any spills or mark the hazard area until it can be
cleaned.
 Notify your supervisor or maintenance personnel.
 Allow an overheated forklift to cool down before removing the radiator cap.
When removing the cap, wear leather gloves and eye protection and open the cap
slightly to check for stored pressure before completely removing the cap. Only
trained and authorized personnel may service a forklift.
Engine temperature gauge
in the normal zone.

33. Slide 33
INSTRUMENTS
TRANSMISSION TEMPERATURE
The transmission temperature warning
light or gauge indicates when the
transmission temperature is too high.
Requirements and Recommended
Practices:
 Do not operate a forklift if the light
comes on or the gauge indicates an
overheated transmission.
Check for leaks. Clean up any spills or
mark the hazard area until it can be
cleaned.
Notify your supervisor or maintenance
personnel.
Transmission fluid may need to be added.
Only trained and authorized personnel
may service a forklift.
Transmission temperature in normal range.

34. Slide 34
INSTRUMENTS
FUEL GAUGE
The fuel gauge shows the amount of fuel
remaining.
Requirements and Recommended Practices:
 Do not operate while extremely low on fuel.
 Check the fuel level during your daily
inspections.
 Refuel only in designated areas. Clean up
any spills or mark the hazard area until it can
be cleaned.
Fuel Gauge

35. Slide 35
INSTRUMENTS
BATTERY DISCHARGE INDICATOR
Electric forklifts have a battery discharge indicator
that shows when a battery charge is low.
Some ways that battery gauges on the instrument
panel indicate the battery is discharged are:
 the warning light indicator is on.
 the gauge needle is in the warning zone.
 a percentage indicator shows the battery charge
level.
Requirements and Recommended Practices:
 Return to the battery recharging area if the
battery gauge is low.
Recharge the battery only if you are trained and
authorized to do so.
Battery Low

36. Slide 36
INSTRUMENTS
HOUR METER
The hour meter records the number of hours
that a truck has been used. It should be
recorded in your Daily Inspection Log.
Maintenance is often scheduled by hours of
truck use, so it is an important indicator.
Requirements and Recommended Practices:
 Log the hours of use daily.
 Do not exceed manufacturer's
recommended hours in service.
 Properly maintain vehicles according to
manufacturer's recommended maintenance
schedule. Only trained and authorized
personnel may service a forklift.
Hour meter indicating the
total time the forklift has
been in service.

37. Slide 37
BATTERY
Parts of An Industrial Battery
1.Cell 
2.Separator 
3.Battery tray 
4.Electrolyte 
5.Element
a)Positive terminal
b)Negative terminal
Requirements and Recommended Practices:
Never accidentally create an electrical current by connecting the positive to the negative
terminal through any part of your body or through any other conductor.
Never wear metal jewelry which will conduct electricity when working around batteries.
Never put metal articles or tools on top of the batteries or place conductive articles across
the battery posts.
Always shut the charger off when connecting or disconnecting the battery. An arc or spark
could cause an explosion.
Use only non-sparking, non-conductive tools.
Keep the vent plugs in place at all times except when adding water to the cells or taking
hydrometer readings.
Check the battery cables and cable connectors regularly. If the insulation is worn or
connector contacts are pitted, the truck should be removed from service and repairs made
immediately.
Follow proper lockout/tagout procedures when working on a battery in a forklift.
Potential Hazards:
 Electrical shock.
 Explosion.
This is a cutaway of an industrial
battery showing the rugged plates,
extra heavy grids and impact-resistant
case.

38. Slide 38
OVERHEAD GUARD
An overhead guard is designed to protect the operator from falling
objects.
Requirements and Recommended Practices:
 Use an overhead guard as protection against
falling objects such as small packages, boxes,
bagged material, etc. Overhead guards are not
intended to withstand the impact of a falling
capacity load.  
 Wear a hard hat for additional protection.
 Keep hands and feet within the forklift to avoid danger of falling
loads.
 Use a load backrest extension whenever necessary to minimize the
possibility of the load or part of it from falling rearward.
 Equip all high-lift rider trucks with an overhead guard manufactured
in accordance with ANSI B56.1-1969, "Safety Standard for Low and High
Lift Trucks," unless operating conditions do not permit.
 As part of the daily inspection of the forklift, check the overhead
guard for broken welds, missing bolts, or other damage.

39. Slide 39
TIRES
There are several different types of forklift tires, depending on
how the forklift is used.
Common types of forklift tires include:
 Pneumatic
 Solid
 Polyurethane
As part of the daily inspection of the forklift, check tire condition,
including cuts and gouges, and check pressure for air-filled tires.
PNEUMATIC - SOLID SOLID POLYURETHANE

40. Slide 40
OTHER SAFETY AND WARNING DEVICES
Powered industrial trucks may be equipped by the
manufacturer with the following safety devices:
 Seat belts and similar restraints
 Horns
 Backup alarms that sound when forklift reverses
 Fire extinguisher
 Warning lights that flash
 Directional signals and brake lights
 Mirrors
Requirements and Recommended Practices:
 Equip every power-propelled truck with an operator-
controlled horn, whistle, gong, or other sound-producing
device.
 Equip every truck with an operator-controlled horn,
whistle, gong, or other sound-producing device. Where
appropriate to the worksite, equip trucks with additional
sound-producing or visual (such as lights or blinkers)
devices.
Source: ANSI/ITSDF B56.1-2005.

41. Slide 41
OPERATING THE TELEHANDLER
PRE-OPERATION
TRAVELLING AND MANEUVERING
LOAD HANDLING

42. Slide 42
PRE-OPERATION
Before starting your vehicle, conduct a pre-operation (or pre-start)
inspection that checks a variety of items, including but not limited to:
Fluid levels -- oil, water, and hydraulic fluid.
Leaks, cracks or any other visible defect including hydraulic hoses and mast
chains. NOTE: Operators should not place their hands inside the mast. Use a
stick or other device to check chain tension.
Tire condition and pressure including cuts and gouges.
Condition of the forks, including the top clip retaining pin and heel.
Load backrest extension.
Finger guards.
Safety decals and nameplates. Ensure all warning decals and plates are in
place and legible. Check that information on the nameplate matches the
model and serial numbers and attachments.
Operator manual on truck and legible.
Operator compartment. Check for grease and debris.
All safety devices are working properly including the seat belt.

43. Slide 43
TRAVELING & MANEUVERING
Mounting and Dismounting
Starting/Stopping
Operating at Speed
Using the Pedal
Steering, Turning and Changing
Direction
Traveling on Inclines
Parking
Safe Travel Practices
Visibility
Tip over

44. Potential Hazards:
Hitting head on overhead cage.
Slips, trips and falls, especially feet slipping off step.
Requirements and Recommended Practices:
Mount the machine and dismount the machine only at locations that
have steps and/or handholds.
Before you mount the machine, clean the steps and the handholds.
Inspect the steps and handholds. Make all necessary repairs.
Face the machine whenever you get on the machine and whenever
you get off the machine.
Maintain a three-point contact with the steps and with the handholds.
Note: Three-point contact can be two feet and one hand. Three-point contact can also be
one foot and two hands.
Do not mount a moving machine.
Do not dismount a moving machine. Never jump off the machine.
Do not carry tools or supplies when you try to mount the machine or when you try to
dismount the machine.
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you enter the operator compartment
Slide 44
MOUNTING AND DISMOUNTING

45. Slide 45
TRAVELING & MANEUVERING
 STARTING
Before starting a forklift, be sure to conduct a pre-operation inspection. In
addition, conduct an operational check after starting the engine.
Perform pre-operation/warm-up of the machine as per machine manual.
Ensure that your way is clear. Sound your horn in warning or use a spotter if your
view is obstructed.
Proceed cautiously down the travel path watching for dangerous blind spots.
 STOPPING
Select an area to park. Do not park in an unauthorized area.
Do not block an aisle or exits. Follow your company's
parking procedures.
Apply brake slowly and stop.
Neutralize the controls.
Set the parking brake.
Turn off the ignition.
If the truck is parked on an incline, block the wheels.
Fasten your seatbelt!

46.  OPERATING AT SPEED
While traveling avoid these potential hazards:
Tip over caused by driving too fast.
Collision with pedestrians and obstacles caused by inattention and
not being able to stop in time.
Requirements and Recommended Practices:
Be aware of the travel conditions along your planned route:
Under all travel conditions the truck must operate at a speed that
will permit it to be brought to a stop in a safe manner.  
The driver must slow down for wet and slippery floors.  
The driver must look in the direction of, and keep a clear view of, the path of travel.
The driver must slow down and sound the horn at cross aisles and other locations where
vision is obstructed. If the load being carried obstructs forward view, the driver shall be
required to travel with the load trailing.
While negotiating turns, speed shall be reduced to a safe level by turning the steering wheel
in a smooth, sweeping motion.
Grades shall be ascended or descended slowly.
When ascending or descending grades in excess of 10 percent, loaded trucks shall be driven
with the load upgrade.
Running over loose objects on the roadway surface shall be avoided.
Slide 46
TRAVELING & MANEUVERING

47. Slide 47
TRAVELING & MANEUVERING
USING THE PEDAL
Proper use of the inching pedal increases the operator's control of
the forklift in tight spaces.
While using the inching pedal, be aware of these potential hazards:
Collision and property damage.
Damage to racking, pallets or load.
Brake failure due to improper use of the inching pedal.
Requirements and Recommended Practices:
Do not "ride" the inching pedal. Premature transmission failure and brake lining wear
may occur as the inching pedal creates a partially disengaged condition.
Depress the inching pedal and slowly approach the load. When the inching pedal is
depressed, the hydraulic pressure to the clutch is progressively reduced, thus
disengaging the drive.
Use the inching pedal when shifting from forward to reverse.
Do not put your foot on the inching pedal or brake pedal unless you are using it.
Tip: Inching pedals may have many special features and advanced controls in larger,
rough-terrain forklifts that have precision transmission inching control for use on
grades.
Operator depresses
inching pedal.

48. Slide 48
TRAVELING & MANEUVERING
 STEERING & TURNING
Most manufacturers design compact telehandlers with two-wheel drive, four-wheel
drive, and crab steering.
While steering, be aware of these potential hazards:
Collision with pedestrians or objects
Falling load following a collision.
Tipover caused by turning too sharply.
Requirements and Recommended Practices:
When turning, reduce speed to a safe level.  
Proceed with caution when making turns, especially when
working in confined areas or narrow aisles.
Anticipate the rear-end swing and start the turn as close
to the inside corner as possible.
Plan your route and anticipate turns. 
Never turn with forks elevated.
Never turn on a grade. The forklift may tip over laterally
on even a very small grade.

49. Slide 49
TRAVELING & MANEUVERING
CHANGING DIRECTION
While changing directions, be aware of these potential hazards:
Tipover.  
Collision with a pedestrian, another vehicle or an object.
Requirements and Recommended Practices:
Come to a complete stop before changing directions.
Keep a careful watch for pedestrians and warn them (e.g., using a horn or warning
light) when reversing.
Operator is releasing the inching pedal, setting the
direction control to forward and pressing the
accelerator. (The brake is the middle pedal.)
Using pedal to shift from
reverse to forward.

50. REVERSING
While backing up or reversing, be aware of these potential hazards:
Pedestrians being struck by or crushed by the forklift.
Collision with another forklift or racking.
Requirements and Recommended Practices:
Keep a clear view.
Look in the direction of travel. When reversing, look behind.
Be aware of limited visibility, and use extreme caution when
driving in reverse.
Consider the use of ground guides, rear-view mirrors, spotters, or other aids to increase
visibility.
Consider the noise level in your workplace. Do not assume pedestrians or bystanders
are able to hear a back-up alarm.
Allow plenty of room for pedestrians. You cannot anticipate what people will do. Many
have no idea how quickly forklifts accelerate and how sharply they turn.
Never assume pedestrians or bystanders are aware of the presence of heavy equipment
and the intended direction of travel.
Do not grab the overhead guard when travelling in reverse. This could expose the
operator's finger to serious injury.
Slide 50
TRAVELING & MANEUVERING

51. TRAVELING ON INCLINES
While traveling on a grade or incline, be aware of these potential hazards:
Tipover
Falling load
Requirements and Recommended Practices:
Drive loaded trucks forward going up a ramp
with the load upgrade and drive in reverse
going down a ramp with the load upgrade.
Always drive unloaded trucks with the forks
downgrade.
Never drive with the load downgrade.
Never turn a forklift on a grade.
Slide 51
TRAVELING & MANEUVERING

52. PARKING
While parking and leaving an unattended vehicle, be aware of these potential hazards:
Danger of an improperly parked truck being struck by personnel or objects.
Danger of unintended movement of the truck.
Requirements and Recommended Practices:
Select a hard, level surface.   
Do not park on a grade, unless wheels are blocked.
Park in authorized areas only, unless the forklift is disabled. Park a safe distance from fire
aisles, stairways or fire equipment. Do not block traffic. 
Fully engage the parking brake.
Lower the load engaging means (lifting mechanism) fully.
Neutralize the controls: Set the direction lever in neutral, and lock the mechanism.
Tilt the mast forward slightly and lower the forks to the floor until the fork tips touch the
floor.
If the lift mechanism is disabled, and the forks cannot be lowered to the floor, attach a
warning tag to the tip of the fork and position the forks away from pedestrians. Do not allow
anyone to stand or pass under the forks.   
Turn the key to OFF, and stop the engine. Remove the key.
Get off the forklift without jumping.
Slide 52
TRAVELING & MANEUVERING

53. While traveling, be aware of these potential hazards:
Overturning forklift
Falling load
Being struck or crushed by forklift
Collisions
Requirements and Recommended Practices:
Always look in all directions before proceeding.
Do not travel with the load elevated.
Watch out for collision with other vehicle/equipment.
Travel at reasonable speed.
Do not engage in stunt driving and horseplay.
Never carry passengers.
Keep arms or legs inside the confines of your vehicle.
Watch for surface obstructions; even a small bump can
cause a load to fall off elevated forks.
Do not travel into a position that a co-worker could be
pinned between the forklift and another object.
Slide 53
 SAFE TRAVEL PRACTICES

54. When visibility is impaired, be aware of these potential hazards:
Collision
Falling load
Falling off loading dock
Worker struck or crushed by forklift
Requirements and Recommended Practices:
Keep a clear view. Look in the direction of travel. When reversing, look behind.
Use spotters, rear view mirrors, or other aids to increase visibility.
Where available, use convex mirrors at blind side intersections.
Use reflective tape if the forklift is driven on facility or public roads. 
Drive slowly into and out of warehouses or other buildings.
Be especially careful on loading docks; stay away from the edge.
Add physical barriers such as ramps, raised concrete staging areas and heavy-
gauge safety chains in front of dock openings. Use protective guard rails.
Add a "warning track" of yellow paint on the floor near dock openings.
Slow down and sound the horn at cross aisles and other locations where
vision is obstructed.
Slide 54
 VISIBILITY

55. There are two basic types of tip over in a forklift:
1)a forward or longitudinal tip, and
2)a lateral or side tip.
IN CASE OF A TIPOVER:
1)Don't jump. Stay in the forklift.
2)Hold tight to the steering wheel.
3)Brace feet.
4)Lean AWAY from the impact.
5)Lean forward.
Slide 55
 TIPOVER
Example of warning label on a powered
industrial truck showing actions to take in the
event of a tipover of a sit-down
counterbalanced truck. Note that the
operator's seatbelt should already be fastened.

56. Slide 56
LOAD HANDLING
Center of Gravity
Load Center
Capacity
Stability
Load Chart

57. Slide 57
CENTER OF GRAVITY
 The forklift truck has a center
of gravity.
 The load has a center of
gravity.
 When a load is on the forklift
we have a COMBINED center of
gravity.
 The COMBINED center of
gravity MOVES as the forklift is
operated and the boom
extended.
SWL of the machine depends on how far
the boom is extended and the angle it is
raised to.

58. Slide 58
LOAD CENTER
IMPROPER LOAD CENTER

59. Slide 59
STABILITY
CAN ONLY BE MAINTAINED BY:
•Knowing the load center
•Knowing the weight of the
load
•Knowing the capacity of the
equipment
•Not lifting when on unleveled
surfaces
•Using Outriggers and / or
Frame Leveling

60. Slide 60
USING THE LOAD CHARTS
1.Check what boom attachment is fitted to your machine,
then turn to the correct Load Chart in the cab.
2. You must know the weight of the load before picking or
placing it. Check that the loads center of Gravity (X) will not
be more than 500mm (20 in) in front of uprights.
3. When you know the weight of the Load, look on the Load
Chart and find the colored segment with the highest
weight.
4. After inserting the forks beneath the load, and before lifting
the load, check the readings on the boom angle and
extension indicators. Find the same readings on the Load
chart.
You will see on the chart that lines run from the boom
angle and extension scales, through the colored area of the
chart. Find where the lines for your readings cross. If they
cross inside your Maximum Load Segment or to the right of
it the load is within safe limits. If the lines cross above or on
the left of the segment, DO NOT TRY TO PICK UP THE LOAD.
Withdraw the forks, retract the boom and try again. If, even
the boom is fully retracted, the boom angle and extension
readings still cross outside your Maximum Load Segment,
DO NOT TRY TO LIFT THE LOAD.

61. Slide 61
USING THE LOAD CHARTS (CONT.)
5. When the load is on the forks, retract the boom before raising or lowering it. This
will reduce the risk of getting the machine unstable. While moving the boom,
watch the boom angle and extension indicators. Keep inside the limits of your
load.
6. Before placing the load, us the Load chart to find how close how close you should
get the machine to the unload point. You must be able to place the load without
crossing the left-hand or upper boundaries of your Maximum Load Segment.
The Load Chart
Uses Boom Angle
AND Boom
Extension to
Indicate the Load
Capacity

62. Slide 62
SAMPLE LOAD CHARTS

63. Slide 63
JOB SAFETY RULES
Hand Signals
Communication
One Contact
Load Guidance

64. Slide 64
JOB SITE / WORKPLACE
•Site Conditions
•Ramps & Inclines
•Operating Area
–Other Equipment
–Vehicles
–Pedestrians
•Docks, Trailers, Rail cars, Semi Trailers

65. Slide 65
YOUR CHOICE – LIVE OR DIE!
WORK SMART
WORK RIGHT
WORK
SAFELY
SAFETY
FIRST - LAST - ALWAYS