SASO & LEEA - Forklift Operator Training Course

Course Outline:

1. Introduction

• Forklift-related Fatalities including (tip-over incidents, pedestrian struck-by accidents, and falling load fatalities)

• Forklift-related Injuries including (crushing injuries, fractures from collisions, foot injuries from wheels, and back injuries from improper mounting)

2. Powered Industrial Trucks (PIT) & Classification of Forklifts

• Powered Industrial Trucks (PIT) including (counterbalance trucks, reach trucks, order pickers, and pallet jacks)

• Classification of Forklifts including (Class I electric motor riders, Class II electric motor narrow aisle, Class III electric motor hand trucks, Class IV internal combustion engine trucks, Class V internal combustion engine trucks, Class VI electric and internal combustion engine tractors, and Class VII rough terrain forklifts)

3. Components of Forklift

• Stability Triangle including (center of gravity principles, load center distance effects, and counterbalance weight function)

• Forklift Control including (hydraulic controls, directional controls, braking systems, and safety switches)

• Mast Lifting Mechanism including (chains, rollers, hydraulic cylinders, backrest, and carriage)

• Rear Wheel Steering including (steering mechanisms, turning radius calculation, pivot point understanding, and maneuverability principles)

4. Forklift Inspection

• Requirements including (pre-shift inspection, post-shift checks, documentation procedures, and defect reporting)

• Inspection Parts including (tires, forks, chains, hydraulic systems, controls, warning devices, brakes, and overhead guard)

5. Forklift Safe Load Handling

• Safe handling preparation including (load weight assessment, center of gravity determination, load stability check, and workplace assessment)

6. Forklift Safe Load Handling

• Safe handling preparation including (assessing load characteristics, calculating maximum capacity, checking load integrity, and planning the travel route)

• Mast position including (vertical mast for traveling, slight backward tilt for stability, forward tilt for load deposit, and proper sequencing of movements)

• Fork position including (proper width adjustment, correct insertion depth, even distribution under load, and load balancing techniques)

• Lifting / Lowering the Load including (smooth lifting operation, load against carriage, proper height maintenance during travel, and controlled lowering)

• High Tiering including (approach alignment, vertical mast positioning, inch control application, and precision placement)

• Loading on truck Trailer including (dock plate inspection, trailer wheel chocking, stabilizer use, and bridge plate positioning)

7. Forklift Safe Traveling, Maneuvering and Operating Rules

• Mounting/ Dismounting including (three-point contact method, facing the forklift, using handholds, and avoiding jumping)

• Starting/ Stopping including (control check before starting, neutral position verification, parking brake application, and controlled stopping)

• Operating at Speed including (speed adjustment for conditions, maintaining safe distances, intersection approaches, and visibility considerations)

• Steering, Turning and Change Direction including (wide turns for loads, pivot point awareness, rear-end swing allowance, and speed reduction before turning)

• Driving on Inclined including (load uphill orientation, maintaining proper clearances, grade assessment, and proper speed control)

• Loading irregular size and loads including (custom fork positioning, load securing methods, visibility accommodation, and special attachment use)

• Safe Travel Practices including (maintaining proper clearances, keeping load low, looking in direction of travel, and using horns at blind spots)

• Safe Refueling / Charging including (designated area procedures, ventilation requirements, spill prevention, and personal protective equipment)

• Forklift Attachments including (capacity derating calculations, proper installation verification, function testing, and operational adjustments)

• Pedestrian Safety including (maintaining separation distances, using warning devices, establishing right-of-way rules, and pedestrian awareness training)