Mr.

Saif Introduction
 Introduction

Operating a forklift requires skill, training, and experience. Although it

may seem as easy and simple as driving a car there are many factors
that make driving a forklift much more difficult.
Learning how to operate a forklift safely can help to prevent damage,
accidental injuries and possible death.
This forklift guide is for either light forklift with an empty weight of not
more than 2.5 tones or a heavy forklift with an empty weight of more
than 7.5 tones.
This guide will help you through the steps of how to operate a forklift
safely. Topics that you will learn in this guide will include safe use of
forklifts, safe operating procedures and pre-operation checks of
forklifts.
 Contents
Mr. Saif introduction…………1
Introduction…………2
Chapter - 1…………4
Types of forklifts……….5
Forklift controls…………….6
Mounting and dismounting……13
Seatbelt……..14
Chapter - 2……………15
Weight of forklift………..16
Forklift stability………..17
▪ Fulcrum point………….17
▪ Center of gravity……18
▪ Stability triangle……….19
▪ Load center……………20
▪ Load plate…………..22
▪ TIPOVER……………………23
Combined center of gravity…….25
Accidents………………26
Driving on inclines………..28
Loading trailer……….29
Wide loads…….30
Unattended forklift……31
Forklift attachments………….32
Chapter - 3……………34
Driving procedure…………..35
Basic Stacking procedure………36
Basic destacking procedure……….40
Chapter - 4………41
Control signs……….42
Prohibitory signs……42
Mandatory signs……43
Warning…………43
Information signs…….45
Road markings………46
PPE signs……47
Chapter - 5……..48
Driver conditions…….49
Alcohol………..49
Medication………….49
Pre operation checks……..50
Daily checks………51
Parking…………….52
Refueling / Recharging……….53
Chapter 1
 Chapter 1

Chapter 1
Introduction to forklift, types of forklifts, forklift
components, forklift controls.
 Types of forklifts

A forklift is a machinery which is used to lift and move large loads. There are
many useful uses for a forklift, many construction sites, warehouses and
manufacturing plants have forklifts. Forklifts come in many sizes and capacities.
They can be powered by batteries, propane, gasoline or diesel fuel.
There are several different types of forklifts that are used in different types of
industries. Some of the types are shown below

Internal Combustion Engine Internal Combustion Engine

forklift with solid tires forklift with pneumatic tires

Electric Counter-Balanced
Electric Aisle with solid
Forklifts with solid and
tires
pneumatic tires

Rough Terrain Forklift with pneumatic tires

 Forklift controls

A forklift operator should be aware of the different parts of forklift in

order to operate the forklift safely and be able to detect when an
unsafe forklift needs to be removed from service. Be sure to familiarize
yourself with the parts on the forklift used within your company.

The diagram above may or may not represent the type of forklift used
in your company.
Your instructor will tell you which type of forklift you will be trained on.

Main Components

Mast

Steering wheel

Operating levers Chain

Lift cylinder

Tilt cylinder

Rear axle

Fork
Front axle
 Forklift controls

Main Components

Overhead guard Lights

Counterweight
Engine hood

Frame

Operator’s seat
 Forklift controls

Main Components

Steering wheel Indicator

Lift cylinder lever

Gear selector

Engine temperature gauge

Fuel gauge

Parking brake lever

Light switch
 Forklift controls

Lift lever:
▪ Pulling this lever backward raises the forks.
▪ Pushing the lever forwards lowers the forks.
▪ Lift speed is controlled by the amount of movement of the lever and
accelerator pedal effort.
▪ Lowering speed is controlled by the amount of movement of the lever. The
accelerator pedal and engine speed have no effect on the lowering speed.
▪ The forks can be lowered while the engine is stopped.

Tilt lever:
▪ Pulling the lever backwards tilts the mast backwards towards the driving
position.
▪ Pushing the lever forwards tilts the mast forward away from the driving
position.
▪ Tilt speed is controlled by the amount of lever and accelerator
movement

Side shifter lever:

▪ Pulling the lever backwards shifts the forks towards the left position.
▪ Pushing the lever forwards shifts the forks towards the right position.
▪ Shift speed is controlled by the amount of lever and accelerator
movement
 Forklift controls

Forward/Reverse lever
The lever shown in image is gear selector for forward and backward
movement. Always come to a complete stop before selection before
selecting forward or reverse direction

Parking Brake lever:

Use the parking brake to hold the forklift stationary when parked.
Remember that the parking brake only operates on the two front
wheels.
 Forklift controls

Internet image

Steering
Operating a forklift is different than driving an automobile. in most
automobiles, the front wheels steer the vehicle, but on a forklift, the
rear wheels control the steering. The rear end of the forklift swings in
a circle around the front wheels.
Because it can swing out further than you expect and possibly cause
an accident, always check to make sure there is enough space for the
rear end to swing

automobiles forklifts
 Forklift controls
Brake Pedal

Accelerator Pedal
Clutch or Inching Pedal

Inching pedal:
Forklifts with torque converter transmissions have similar foot controls to a
manual vehicle, but in place of a clutch pedal, they have an inching pedal.
As you press the inching pedal oil pressure in the torque converter drops,
allowing you to perform inching operation. Use this pedal to hold the forklift
stationary while operating the hoist system at a higher rpm level.
The inching pedal must not be used on inclines or where engine braking is
required.
Allow the engine rpm level to return to idle before releasing the inching pedal.

Brake pedal:
The brakes on a forklift operate only on the drive wheels (the two main front
wheels). You should never apply the brakes suddenly. It should always be a
gradual action to ensure you do not compromise the security of the load.
The brake should always be used to slow the forklift down, not the inching
pedal.

Accelerator pedal:
The accelerator is the right hand foot pedal and will accelerate or decelerate the
forklift.
When using this pedal, use gradual movements to ensure no jerking or sudden
movements.
 Mounting / Dismounting

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Special precaution should be taken when mounting and dismounting forklift so

that you don’t slip, trip or fall. The correct way to mount the forklift requires
you to use three points of contact which acts as a support system to prevent
you from falling.
This means that both of your hands and one foot should be in contact with the
forklift at all times. Additionally, you should always mount and dismount the
forklift on the side without the gearshift. Never jump on or off of the forklift.
 Seatbelts

Seatbelts

You are required to use seatbelt when it is supplied with the forklift. It
will save your life.
 Chapter 2
Forklift Stability, Center Of Gravity,
Driving Surfaces, Forklift Attachments
 Weight of a forklift

Although a forklift is smaller than a car, a forklift may be two to three

times Heavier.
Average forklift can weigh from 3,000 to 4,500 pounds. In order to
balance heavy loads and help prevent the forklift from tipping over, a
large counterweight is mounted on the rear of the forklift.
This counterweight is a part of the forklift's structure and should
never have anything added to it in an attempt to
balance the load out.

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 Forklift Stability

Forklift stability is an important topic because the leading cause

of death and serious injury involving forklifts stems from
overturns caused by forklift instability.
Forklift stability can be described by four elements:
▪ The fulcrum point,
▪ center of gravity,
▪ the stability triangle and
▪ the load center.

Fulcrum Point
Forklifts are counter balanced and work on a see-saw principle.
The point of balance of the forklift is called the Fulcrum.
On a forklift, the fulcrum is the front axle (drive axle).
The weight of the forklift behind the front axle, balances the
weight of the load on the forks.
The diagram below displays this concept.
 Forklift Stability
Center of Gravity (CG)
The center of gravity is the point in an object at which all of an objects
weight is concentrated and is the balance point.
With some loads, the center of gravity may change. Example, a drum
that is not full, will have a lower center of gravity than a full drum.
With many loads, the center of gravity may not be in the center. These
should be carried with the heaviest end of the load towards the
backrest.
As a driver it is important to remember that a new center of gravity is
created when you're handling a load, both the load's and the truck’s
center of gravity combined.
 Forklift Stability

Stability Triangle
Think of the stability triangle as three imaginary lines that are
connected by the center axle to the front wheels of the forklift.
In order to maintain a stable forklift, you must keep the center of
gravity within the stability triangle or it will tip over. The most stable
area while handling a load is close to the base of the forklift.
If the load you are carrying moves too far forward from the forklift's
base, it will more than likely tip forward.
 Forklift Stability

Load Center
The load center of a forklift is simply the distance from
the front face of the forks to the center of the load. The most
important thing to remember is that the further you move from the
load center when moving a load, then the lower capacity your truck
will be able to handle.
The maximum capacity of forklift can be found on the data plate of
the forklift.
 Forklift Stability

Formula To Calculate New Load Center

2500 kg

3500 kg

700 mm
500 mm

3500 X 500 ÷ 700 = 2500 kg

Max Load Capacity (kg) X standard Load Center (mm) ÷ New

Load Center (mm) = New Max Load (kg)
 Load plate

Load Plate
The load capacity plate also known as load chart , by which the
operator can determine what weight the forklift can safely lift,
to what height, given what load centre.
If the load is not uniform then the heaviest portion should be
placed closer to the backrest, for stability, and
centered on the forks.
Handle only loads within the rated capacity of your forklift as
shown on the forklifts capacity plate.

Distance from back end of fork

= 24 inches = 600 mm

Weight capacity = 5000

pounds =2200 kg

New distance from back end of

fork = 30 inches = 760 mm

New Weight capacity = 4350

pounds =1900 kg

If attachments get fitted to a forklift, a new load rating chart

needs to be issued for the machine as adding attachments
lowers the lifting capacity of the machine.
 TIPOVER

Some factors that could cause tip-over are:

▪ Carrying the load too high.
▪ Excessively tilting the load forward.
▪ Operating on a decline.
▪ Heavy braking.
▪ Inappropriate use of forklift attachments.
▪ Off-center loads.
▪ uneven terrain.
▪ Quick turns.

However, your potential to turn over can be reduced if you follow few
safety rules:
▪ Make sure the load is stable and safely arranged on the forks.
▪ Do not tilt the forks forward except when picking up or keeping a load.
▪ Keep the load low just above the pavement with the forks tilted back when
traveling.
▪ Enter tractor-trailers or elevators squarely when picking up or keeping
loads.
▪ Drive at a slow enough speed to allow you to stop safely.
▪ Drive slowly on wet or slippery surfaces.
▪ Avoid driving on unstable surfaces or where there are loose objects on the
surface
 TIPOVER

What do in case of a tip-over?

If the forklift tips, keep your arms and legs inside and hold on to the steering
wheel. Don’t attempt to jump out – you can’t move faster than the forklift can
tip over. Most people who attempt to jump are killed by the impact of the
overhead guard.

Tipover procedures for other types of forklifts may vary. For example operators of stand-up forklifts with rear-entry access
should step backwards off the forklift if a tipover occurs.
 Combined Centre of Gravity

The combined centre of gravity of the forklift and the load can move.
As seen in this picture, when the load is raised, the combined centre of gravity
raises as well. The higher the combined centre of gravity is, the more unstable
the forklift becomes. In this picture, the combined centre of gravity has raised
with the load. When the driver has tilted the mast forward, due to the combined
centre of gravity being so high, it has moved quite a distance forward as the
mast has gone forward. This forklift would have tipped forward as well. If the
combined centre of gravity was lower, it would not move as far forward as it has
at the higher height.
A forklift is not as stable laterally as it is longitudinally. This is because of the
narrow track of the wheels. A forklift should never be driven sideways along or
turned on an incline as it is easy for the combined centre of gravity to move
outside the ‘Stability Triangle’.

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 Accidents

Common Causes of Accidents

• Travelling at excessive speed.

• Riding with the load elevated.
• Turning on ramps or inclined areas
• Improper backing up techniques.
• Improper turning, breaking or accelerating.
• Improper warnings to others about a forklift in use nearby.
• Poor communication during shared tasks, or in shared spaces.
• Riding or giving rides on forklift or load.
• Parking the forklift improperly.
• Improper blocking of wheels on semi-trailers.
• Horseplay; stunt driving; jerky, erratic driving.
• Inadequate servicing of the forklift.
 Accidents

People on Fork-Lifts

▪ Do not allow passengers on the fork-lift unless there is a separate

seat
▪ Do not lift people on the fork arms or a pallet

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 Driving On Incline

Always drive with the load on the uphill side - go backwards driving
down the incline and frontwards going up the incline to prevent
tipping or losing control of the forklift.

If no load on the forklifts, do the opposite with forks pointing down

the ramp
 Loading Trailers

Make sure:
▪ Truck trailer wheels are properly chocked,
▪ Dock board is secure and can handle weight,
▪ You use horn when exiting trailer.

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 Wide Or Irregular Size Loads

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▪ Distribute the weight evenly when carrying irregular sized loads.

▪ Keep the center of gravity of the load as near as possible to the
center going horizontally across the forks.
▪ Keep the center of gravity of the load as near to the front wheels as
possible.
 Unattended Forklift

Don’t leave your forklift unattended

A forklift is considered "unattended"

When the operator is 25 ft. or more
away from the vehicle even if it
remains in his view, or whenever the Internet image
operator leaves the vehicle and it is
not in his view.

When a forklift is left unattended,

forks must be fully lowered, controls
neutralized, power shut off, and
brakes set. Wheels must be blocked if
the truck is parked on an incline. Where’s the operator??

When the operator of a forklift is within 25 ft. of the truck still

in his view, the load engaging means must be fully lowered,
controls neutralized, and the brakes set to prevent
movement, but the power does not need to be shut off.
 Forklift Attachments

Carpet Pole
This is used for picking up rolls
of carpet. It picks up from the
middle of the carpet roll.
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Barrel Clamp
This attachment is used for
picking up drums. Should be
used around the middle of the
drum.

Fork Extensions
These are commonly used to
pick up two pallets at a time.
This is usually done to load
both sides of a truck at the
same time from the same
side. Internet image
 Forklift Attachments

Jib Attachment
Used for picking things up with a
sling, like a crane.

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Paper Roll Clamp

Used for picking up large rolls of
industrial paper. Can also rotate.

Work Platform
These are used to lift personnel to
heights to make repairs on
machinery or plant. They must
have a barrier at the back to stop
anything falling into the mast area.
 Chapter 3

Chapter 3
Operating Procedure, Stacking And Destacking
 Driving procedure

Always look in the direction of travel

and keep a clear view of the way
ahead.

Remember the effect of tail swing. To

make a turn, slow down and take care
that the tip of the fork or load or rear
side of the forklift does not hit any
object or person.

If large load obstructs forward vision,

drive in reverse.

Only carry loads that are supported by

the forklift and its backrest extension.

Drive at appropriate speed with the

conditions. Slow down for wet or
slippery surfaces.
 Driving procedure

Keep a safe distance from other

vehicles in front and never overtake
when approaching cross roads or in
blind areas

If vision is obstructed keep well to the

correct side of the aisle when
approaching crossings in aisles, slow
down and sound horn,

Passengers must not be permitted to

ride on the forks or load or any other
part of a forklift truck.

Never use a forklift as a lift for people

unless a work platform has been
fitted.

Avoid making fast starts, jerky stops,

and quick turns, particularly if
materials are being stacked at height.
 Driving procedure

Do not allow anyone to stand or walk

under the elevated forks, whether or
not a load is being carried.

Never attach a tow rope to the mast to

pull other machines or drag loads.

When traffic signs and signals are in

use, learn and act upon them.

Never handle loads that exceed the

forklift truck’s rated capacity, also
considering combined load centre.

Drive carefully and slowly, especially

when pedestrians are about.
 Driving procedure

Never drive over a bridge plate unless

you are satisfied that it will support
the weight of your forklift and load
and it is securely fixed. Drive over very
slowly.

Before entering a truck or trailer, its

brakes should be set and its wheels
chocked. Semi-trailers must have fixed
jacks to prevent upending.

When travelling on an incline and

carrying a load, the load must always
be on the uphill side of the forklift
truck.

When travelling on an incline without

a load, the forks must always be on the
downhill side of the forklift truck.

On all gradients, the mast must be

tilted back sufficient to safeguard the
load and the forks raised high enough
to clear the ground.
 Basic Stacking Procedure
Approach the stack with the load low and
tilted backward.
Slow down and stop at the face of the stack,
reducing backward tilt to an amount just
sufficient to stabilize the load. Handbrake on,
gear lever in neutral.

Raise the load to the desired stacking height.

The mast should almost be vertical with just a
little bit of back tilt to stabilize the load.

When the load is clear of the top of the stack,

move slowly forward.

When the load is over the stack, bring the

mast to the vertical position and lower the
load on to the stack.

When the load is securely stacked, lower the

forks until free of the pallet and withdraw by
reversing the forklift truck. At this position
slight forward tilt may be of assistance,
otherwise it should rarely be necessary to use
forward tilt.

When clear of the stack, tilt the mast

backward and lower the forks to just above
the ground level.
 Basic Destacking Procedure

Halt at the face of the stack, bringing the

mast to the vertical position

Raise the forks to a position permitting clear

entry into pallet or dunnage strips.

Slowly drive forward until the back-rest is

against the load. Slight forward tilt may be of
assistance at this stage.

Lift the load until clear of the stack and apply

backward tilt just sufficient to stabilize the
load.

When the load is clear of the top of the stack,

move slowly backward to clear the face of the
stack.

Lower the load to the correct carrying

position, before applying further backward
tilt.
Extreme care must be taken to avoid jerking
when tilting a load forward or backward,
especially when the load is at height.
 Chapter 4
Control Signs, Mandatory Signs,
Warning Signs, Information Signs, Road
Markings, PPE,
 Signs and Markings
Control Signs

Stop Give Way Give Way To Maximum Maximum No Horn

Pedestrians Height Limit Width Limit

Prohibitory Signs

Maximum No U- Turn No Parking No Overtaking Priority To No Right Turn

Speed Limit Oncoming
Traffic

No Power No Entry No Lorries No Stopping No Waiting No

Driven Vehicles Unauthorized
Vehicles

No Cyclists No Pedestrians No Hazardous Maximum No No Forklift

Materials Speed Limit Motorcyclists
 Signs and Markings

Mandatory Signs

Roundabout Ahead Only Pass Either One-way Right Only Keep Right
Side

Warning Signs

Maximum Roundabout T Junction Cross Road Two Way Traffic Merges

Headroom At Ahead Ahead Ahead Traffic From Right
Hazard Ahead Ahead

Bend To The Steep Hill Steep Hill Down Opening Bridge High Voltage Traffic Merges
Left Ahead Upwards Wards Overhead To The Left
Cables Ahead

Bends Ahead Right Side Road Road Narrows Road Narrows Road Narrows Traffic Light
Ahead From Left From Right From Both Ahead
Ahead Ahead Sides
 Signs and Markings
Warning Signs

U Turn Ahead Pedestrians Animals Ahead Children Quay Side Or Tunnel Ahead
Crossing Ahead River Bank
Ahead

Other Dangers Dual Carriage Risk Of Falling Slippery Road Uneven Road Loose
Way Ends Rocks Ahead Ahead Chippings
Ahead

Low Flying Cyclists Ahead Road Ends Que Of Traffic Left Lane Ends Staggered
Aircraft Ahead Ahead Junction

Right Lane Stop Ahead Give Way

Ahead Ahead
 Signs and Markings

Information Signs

Countdown markers Start of End of freeway parking

freeway

Road clear No through Hospital Priority over Lane open Lane closed
road oncoming
traffic

Reflective Handicapped
markers parking
 Signs and Markings

Road Markings

Stop Line Give Way Line Traffic Lane Arrows

Solid Center Center Lines Broken Center Hazard Broken Edge Of Solid Edge Of
Line Restricts Restricts Line Warning Center Road Marking. Road Marking
Overtaking Overtaking Line
From Both From Right Side
Sides

Move As Deceleration
Indicated Lane On The
Right
 Personal protective Equipment

PPE ( Personal Protective Equipment)

Safety Shoes Safety Gloves Respirator Helmet Dust Mask Safety Glasses

Protective
Clothing
 Chapter 5
Driver conditions, pre-trip inspection,
parking, refueling.
 Driver conditions

If you are going to operate a forklift:

▪ Don’t drink alcohol
▪ Don’t use drugs
Don’t put your life and the life of others in danger

Alcohol
Alcohol can affect your operating skill by Alcohol Or
causing:
Medication
▪ Impaired vision
▪ Difficult to concentrate
▪ Difficulty in sensing risks
▪ Increased reaction time

Medication
Some medication may cause reactions that
are be unsafe for driving or using mechanical
equipment. These reactions may include
drowsiness, dizziness and inability to focus.
Always check with your doctor or pharmacist
if the medicine would contain such Fatigue
reactions. If you have to use medicine refrain
from driving.

Distracted
 Pre-operation Inspection

Pre-operation Inspection

• As an authorized operator, it is your responsibility to make sure your

forklift functions properly
• Any defect with the forklift must be reported immediately to the
supervisor.
 Pre-operation Inspection

Daily Checks
At The Start Of Each Day, The Following Should Be Checked On Your Forklift:
• Fuel Level
• Fuel Leaks;
• Engine Oil Level
• Water Levels;
• Hydraulic Oil Levels
• Hoses Connections (Damage Or Leaks)
• Battery Fluid Levels;
• Tires ( Air Pressure, Damage)
• Horn And Reverse Alarm
• Steering Ply,
• Brakes (Grip And Lag)
• Hydraulic Jacks And Lift Chains.
• Walk Around To Debris On Ground
 Parking

Parking
• Lower the forks.
• Set gear to neutral.
• Set the parking brake.
• Remove key.
 Refueling and Recharging

Refueling and Recharging

• Park in designated refueling or Recharging area.

• Do not block emergency equipment or emergency exits.
• Have extinguisher nearby.
• Turn off engine and lights.
• Use PPE.
• No Smoking nearby.
• Avoid Spilling fuel.
• For LPG, shut off valves.
• When charging, remember toxic gases are produced so area needs to be
well ventilated.