Forklift Telehandler ONLY Operator Training Revised_7.6.2022.pptx

OPERATOR TRAINING
U.S. - FORK TRUCKS
Rough Terrain Forklifts
Straight Mast and Telehandlers
 In Compliance With
OSHA, CSA and ANSI/ITSDF Standards

TABLE OF CONTENTS
2
Introductions
Training Objectives
Types of Equipment
Pre-Start Inspection
Safe Operation
What Can Go Wrong?
Parking & Shut Down
Test
Summary
Hands-On Assessment

INTRODUCTIONS
© 2022 Sunbelt Rentals, Inc., All Rights Reserved
3

INTRODUCTIONS
4
 Instructor
 Attendees
–Name
–Background
–What do you hope to learn?
 Please silence your cell phones
 Breaks at 90 min
 Fire Exits, Rest Rooms

 We hope that this aids you in understanding
how to use lift equipment
 Please use only as guidelines
 Refer to the OSHA standards and regulations
for construction projects
 The Operator Manual is the presiding text on
the safe operation of the Forklift, Read and
understand it
INTRODUCTIONS
5

TRAINING OBJECTIVES

INTRODUCTIONS, GEAR QUIZ
Name 3 things you need to know about Forklifts before operating?
6
1 Get training
2 Read the operator’s manual
3 Conduct a pre-start inspection
Stay away from power lines
5
4 Conduct a workplace inspection
6 Read and understand the load charts or ID plate
7 The weight of the load
8 The capacity of the forklift
9 Any attachments
10 Do not lift personnel
11 Do not alter the forklift in any way
12 Don’t operate a forklift that is not operating properly
13 Follow all Jobsite Rules and procedures
3

TRAINING OBJECTIVES
8 © 2022 Sunbelt Rentals, Inc., All Rights Reserved
An understanding
of your
responsibilities
An understanding
of the various
types of lift
equipment
An understanding
of a workplace
inspection
An understanding
of the hazards
involved
Written exam
Must get 32 out of
40 correct
Hands-on
training and…
How to
prevent
accidents
Course Objectives and Goals
To provide the student with:
An understanding
of a pre-start
inspection

TRAINING OBJECTIVES
9
How Hydraulic Equipment Works
Fluid
Pump
Valve
Cylinder
or Drive
Power

TRAINING OBJECTIVES
10
Only qualified personnel
shall operate the equipment
Each machine is different
 Read operator’s, AEM
manuals
 Give yourself time to get
familiar with the controls
 Trained per OSHA CSA ANSI/ITSDF
 Authorized by the employer/user
 Familiarized

TRAINING OBJECTIVES
 85 forklift fatalities and
 34,900 injuries each year
 Millions of $$ of lost production
 Untold misery and loss to families,
relatives and friends
What accidents have you seen,
witnessed or experienced?
7
Accidents cost everyone!!!

TRAINING OBJECTIVES
12
The Most Serious Accidents
24%
17%
14%
14%
11%
8%
6%
Tip Over
Struck by Material
Struck by Forklift
Worker Fell from Forklift
Worker Pinned Between Objects
Forklift Ran Off Dock
Worker Died During Forklift Repair

TRAINING OBJECTIVES
13
Definitions
 Telehandler Forklift - a device designed to lift and
transport materials that is used on rough terrain, has a
telescopic boom that raises and lowers, typically with
6k to 15k lbs. of capacity
 Warehouse Forklift- a device designed to lift and
transport materials on a smooth flat and level surface
usually concrete to load/unload trucks and shelves
 USERS – person or entity that utilizes or puts into
operation the lift. (includes companies and
supervisors, etc.)
 OPERATORS – a qualified person who controls the
movement of the lift

TRAINING OBJECTIVES
14
Training Required
 OPERATOR TRAINING:
–Ensure that the individual has been trained
Retraining as necessary to restore proficiency
Change in worksite
Change in equipment
Accident or near miss
Or recognized deficiency Outriggers Articulating boo lifts
Policy: retraining every 3 years or any of the above.

1. Accidents cost __________.
2. Only _________________ shall operate the equipment.
3. Name two of the most common Forklift accidents?
TRAINING OBJECTIVES - GEAR QUIZ
15
everyone
qualified personnel
5 Worker Pinned Between Objects
1 Tip-over
2 Struck by Material
Struck by Forklift
3
4
Worker Fell
From Forklift
7
Worker Died During
Forklift Repair
6 Forklift Ran Off Dock
5

TYPES OF
EQUIPMENT

TYPES OF FORKLIFTS
12
Classes of Lift Trucks
 Powered Industrial Trucks
–Class 7, Rough Terrain
 Straight Mast
 Telehandler
 Trailer Mounted Forklifts “Moffitt”

TYPES OF FORKLIFTS
18
Telehandler Rough
Terrain Forklift
 Reaches to Greater Heights
 Adjustable Frame
 Multiple Steering Modes
 Oscillating Axle
 a.k.a., Reach Lifts, Shooters, Lull, Telehandler.
 JLG, Skytrak, Cat, JCB Loadall, Genie

TYPES OF FORKLIFTS
19
Vertical Mast RTFL
 Steering Primarily through Rear Wheels
 Mast Tilt Feature
 Carriage Shift Feature
 Tight Turning Radius
 Efficient in Storage Rack Areas
 JCB, Case

TYPES OF FORKLIFTS
20
Questions to Determine the
Correct Forklift for the Job
 How high do you need to land the load?
 How close can you get the forklift to the work?
 How much weight are you lifting?
 Inside or outside?
 Electric, Gas/LP, Diesel
 Path from drop off area to work area?
 What work are you doing?

TYPES OF EQUIPMENT, GEAR QUIZ
21
1. Rough terrain reach forklifts are also known as:
1. Shooters
2. Lulls
3. Telehandlers
4. All the Above
2. An important question to ask when selecting any forklift
is:
_______________________.
How much am I picking up
7

PRE-START INSPECTION
23
Steel Toe Work Boots
Hardhat, overhead hazards
Safety Glasses Seatbelt
Safety Gear
 Starts with YOU, are you Fit for
duty and properly protected?
–Hard hat
–Steel toed work boots
–Safety glasses
–Hi-Vis Vest
–Seatbelts
Reflective HiVis Vest

24
Before the Start of the Day or Before the Start of the Work Shift
Operating & emergency controls
Safety devices, backup alarm & horn
Fire extinguisher, mirrors, personal
protective devices, hardhat, safety boots,
safety glasses, seatbelt
Air, hydraulic, & fuel system leaks
Cables, wiring
Loose, missing parts
Tire, wheels
Grab handles and steps
Forks
Placards, warnings, control markings, manuals
Outriggers, stabilizers, other structures
ROPS
Items specified by manufacturer, Manuals
All defects shall be corrected before use

25
Common Problems
 Seatbelts not working
 Control markings illegible
 Load charts missing
 Forks damaged
 Fuel not clearly marked
 Brakes not working
 Fire Extinguisher, Charged, Tagged
 Manuals missing
 Altering safety devices. Altering or disabling of
interlocks or other safety devices shall be prohibited.

26
Hydraulic Leaks
 Do not put your hands around hydraulic lines
especially if you suspect a leak
 High pressure injection injuries can be fatal
 If injured by high pressure injection seek
professional medical attention IMMEDIATELY
from a HAND SPECIALIST!!!
 Your life or limb may depend on immediate
action
 WARNING! – Graphic slide is next!

27
This is NOT the injury but the operation to remove the oil from the
muscle tissue.
High pressure hydraulic
injection injury, man was
wearing leather gloves at
the time as well. Mineral oil
ate away at the fatty tissues
in his hand and began
traveling up his arm.
High Pressure
Injection Injury

28 These Forks are Worn more than 10%.
Fork Thickness Heel must be at
least 90% of fork vertical shank
thickness, OSHA and ANSI.
Blade
Shank

29
2.2 lbs. = 1 Kg.
600 mm = 24 Inches
1250 kg = 2750 lbs.
Fork capacity:
Each fork must match, be marked and the
combination of the two forks must be equal to
or greater than the forklift capacity, per ANSI.
Fork capacity Example:
If forklift capacity is 5,000 lbs. each fork must
have a capacity of 2,500lbs.

30
 Surface cracks, visual check or non-destructive
testing
 Straightness of blade and shank, within 0.5% of
length of blade or height of shank
 Fork angle from upper face of blade to load face of
shank, within 3 degrees of original
 Relative height of fork tips in set when mounted on
fork carrier, difference of height not to exceed 3% of
length of blade
 Operation of positioning lock (if provided), good
repair and correct operation
Fork Inspection per ANSI/ITSDF
The forks shall be carefully examined for the following:
 Wear, especially in the area of heel, Thickness
shall be within 10% of original specification or not
less than minimum thickness as specified by the
fork manufacturer
 Fit of fork arm mounting hooks or eye, visual
check for fit with no excessive wear or deformation
between hooks and carrier of fork eye and shaft
 Markings, shall be legible

31
Manuals
 Operator’s Manual
 AEM Yellow Manual
 Manuals for attachments when applicable

32
 Check fuel, what kind?
–Do NOT run out of fuel!
–Some lifts will not restart
if low on fuel
 Check DEF,
(Diesel Exhaust Fluid)
 Watch regen status
indicator
 DO NOT BYPASS
REGEN!!!
Maintenance
 Check oil
 Check radiator,
cold
 Watch gauges
 Check fan belts
 Check hoses
 Check tires
 Check batteries

33
Refueling
Do NOT Run Out of Fuel!!!
 Attend fuel nozzle
 Do not overfill
 Report spills
and…
 Do NOT run out
of fuel!!!
 Shut engine off
 DO NOT SMOKE
 Keep sparks and
flame away
 Do not cut or weld
 Know the type of fuel
Newer Diesel engines will shut off
when tank is near empty and will not
restart, add fuel to restart.

Tires and Wheels
 Loose or missing lug nuts
 Missing bearing caps
 Leaks
 Most telehandler tires are foam filled or
solid
 Non-Marking white or gray tires require
a static strap under the lift that drags on
the floor to dissipate the static charge
(NFPA standard)
34
Note: Foam Filled
There is a plug lag bolt in the tire directly
opposite from the valve stem

RED –
Immediate
hazards which
WILL result in
severe personal
injury or DEATH.
35
Notice decal -
indicates “Gas”
“Diesel”
“Hydraulic Oil”
ORANGE –
Hazards or
unsafe practices
which COULD
result in severe
personal injury
or death.
YELLOW –
Hazards or
unsafe practices
which COULD
result in minor
personal injury
or product or
property damage.
Definitions of labeling:
28

Troubleshooting
 Forklift will not start
–Is the gear selector in neutral
–Is the parking brake set, electric or manual
–Are you turning the key all the way (JCB Loadall)
 Forklift will not move or moves slowly
–Check parking brake
–Telehandler – check gear selector rotate to 1st or
2nd gear
–If stuck, rotate gear selector to 1st gear, use
differential lock if equipped
36
Starting – Left foot brake, gear
selector in neutral, parking brake
set, turn the key

PRE-START INSPECTION, GEAR QUIZ
37
Name 3 things to check on a pre-start inspection.
1 Operating & Emergency Controls
2 Safety Devices
3 Personal Protective Devices, Hardhat, Safety
Boots, Safety Glasses, Seatbelt, Horn, Mirrors
Cables, Wiring
5
4 Air, Hydraulic, & Fuel System Leaks
6 Loose, Missing Parts
7 Tires, Wheels
8 Placards, Warnings, Control Markings, Manuals
9 Outriggers, Stabilizers, Other Structures
10 ROPS
11 Grab Handles and Steps
12 Forks
13
Items Specified By Manufacturer’s Operating
and Safety Manual
9

SAFE OPERATION
39
3 & 4 points of contact getting into the seat.
Mounting and Dismounting
 A forklift is unattended when out of view of the operator or
the operator is more than 25 feet from the forklift
 A forklift is attended when the operator is within view and
the operator is not more than 25 feet from the forklift
 Three Point Contact
–Clean shoes off
–Two feet and one hand or
–Two hands and one foot always on the machine
or ground
–Face the machine
–Sit in the seat, adjust the seat, fasten seatbelt
–Do not get off, unless forklift is properly shut down
–Do not swing off, slide out, etc.
–Exit facing the machine, maintaining the “Three Point
Contact”

SAFE OPERATION
40
Hazard or Risk Assessment
The process to identify potential hazards associated with
a task and work environment where the task is to be
performed and the development of methods to remove or
control the risk to workers from identified hazards.

SAFE OPERATION
41
What are some hazards you should be aware of when operating a Forklift?
Untrained Operator
Right Forklift for the Job
Ground Support, Firm and Level
Pedestrians and Other Equipment
Ramps, Drop-offs, Holes
Housekeeping, Debris, Cords, Hoses
Obstacles Overhead
Wind, Weather and Lightning
Enclosed Environment, Carbon Monoxide
CO Poisoning
Power Lines
Reporting potentially hazardous locations. The
operator shall immediately report to his supervisor
any potential hazardous location(s) (environment)
which become evident during operation
If any of the above conditions change, STOP,
consult your supervisor

If any of the above conditions change, STOP, consult your supervisor
SAFE OPERATION
42
Hazard Assessment - Hazard & Correction
Operator and
spotter trained.
Public roadways,
spotter, signal
person.
Surface and soil
conditions where
the forklift will be
operated; including
sufficient strength to
withstand all floor/ground
load forces imposed by
the forklift in all operating
configurations. See
operator's manual.
Will the forklift reach
the landing area?
Verify load chart
range and capacity
of what you are
lifting

SAFE OPERATION
43
Pedestrian traffic
where the lift will be
operated -
barricades, traffic
control, spotter.
Precautions for
other moving
equipment -
barricades, traffic
control, spotter.
Ramps and other
sloped surfaces that
could affect the
vehicle's stability,
spotter.
Spotter is required
in narrow aisles
and near all critical
equipment and
piping, construction
or live units

SAFE OPERATION
44
Bumps or
floor
obstructions.
Keep the
telehandler level
when traveling
and before lifting
Debris,
housekeeping,
pick up debris.
Overhead
obstructions
Spotter
required
Drop-offs or
holes,
including those
concealed by
water, ice, mud,
etc..
Electrocution
hazards, stay
20 feet away or
notify power
company to Lock
Out power. Observe
minimum approach
distance. Spotter
required

SAFE OPERATION
45
Wind and weather
conditions –
lightning within 6
miles, wind limited
to manufacturers’
requirements.
Other possible
unsafe
conditions.
Refer to pre-task
assessment,
MPW, STA, JSA,
TSA
Hazardous
environmental
locations where the
vehicle will be
operated. Explosion
or fire hazards
Closed
environments and
other areas where
insufficient
ventilation or poor
vehicle maintenance could
cause a buildup of carbon
monoxide or diesel
exhaust.

SAFE OPERATION
46
Racks and Narrow Isles
Be aware of
 Maneuverability
 Overhead obstructions
 Visibility, sound horn, use your mirrors
 Pedestrians
 Other vehicles
 Can racks support the load

SAFE OPERATION
47
Railroad Tracks
 Do not park or store materials within 25 feet
of railroad tracks
 Cross tracks after Stopping and making sure
the track is clear of moving cars
 Cross at an angle, slowly

SAFE OPERATION
48
 Power Line Clearances
 Minimum Approach
Distance
 Some may require a power
line Proximity Permit
Voltage Range
0 to 350kv 20 feet
350kv to 500kv 25 feet

SAFE OPERATION
49
Minimum Safe
Approach Distance
 If you have contacted a power line, DO NOT step off the
lift. Stay with it and try and back the lift out of the line.
 If you cannot back it out of the line, stay with the machine
and call for help.
 If you are in danger because the lift is on fire and you must
exit, DO NOT STEP OFF.
 You must jump off with both arms and hands wrapped
around yourself and you must land on both feet and not fall
against the lift or the ground.
 You must then shuffle your feet without picking them off the
ground away from the lift and away from the power line.

SAFE OPERATION
50

SAFE OPERATION
51
Percent Slope to Degrees Conversion
Percent % Slope 0 10 20 30 40 50 60 70 80 90 100 120 140 170 200
Degrees 0° 6° 11° 17° 22° 27° 31° 35° 39° 42° 45° 50° 55° 60° 64°
Percent Slope of 10% 1 2 3 4 5 6 7 8 9 10
1 foot rise on 10 foot of run –
10% slope or 6°
Slope vs. Degrees
They are not the same

SAFE OPERATION
52
Operator frame tilted to the right to place steel columns.
Frame tilt/level is ONLY to be used to LEVEL the forklift,
NOT to un-level it
Driving while boom elevated
Tip Over Accidents
Elevate ONLY on flat, firm, level ground!!!

SAFE OPERATION
53
 What is a forklift?
–Lever
 Stability
–Law of Physics
 Attachments (ONLY MANUF.
APPROVED)
–Man Baskets
–Other Fork Attachments
 Load Chart Understanding
–Telehandler Load Charts
–Warehouse ID Plates

SAFE OPERATION
54
Manuals, Warning Labels, ID Plates and Load Charts
 Operators Manual
–Read it!
 Warning Labels
–Legible
–Read and Heed
 ID Plates
–Read and Understand
 Load Charts
–Telehandlers
–Read and Understand

SAFE OPERATION
55
Site Specific Rules
 PPE
 Speed Limits
 Hand Signals
 Signs
 Communications
 Training I.D.
 Reflective Fluorescent Vest

SAFE OPERATION
56
Typical RT Straight Mast Controls
Transmission Shifter,
Forward, Neutral, Reverse
1
Gauges, Fuel, Water Temp.,
Oil Pressure, Engine RPM…
2
Fork and Mast Controls,
Up & Down, Mast Tilt,
and Side Shift,
4th Lever Fork Adjuster
3
Key Switch, Horn,
Lights, Accessories
4
Brake Pedal,
Accelerator
5
Parking Brake
6

SAFE OPERATION
57
Typical Telehandler Controls
Transmission Shifter, Forward,
Neutral, Reverse, may also
include speed/shifter
1
Gauges, Fuel, Water Temp.,
Oil Pressure, Engine RPM…
2
Horn, Key Switch,
Lights, Steer Mode
Switch, Accessories
4
Frame Tilt Indicator
3
Boom Up, Down,
Extend, Retract, Fork Tilt,
Frame Tilt/Level
5
Outrigger Stabilizers,
if equipped, 10k 12k
6
Brake Pedal, Accelerator
7
Electric Parking Brake
8

SAFE OPERATION
58
Typical Telehandler RT Controls
Boom Down
Boom Up
Tele Out
Tele In
Note: Dial,
Rocker switch or
Button will be
Fork Tilt
Fork tilt down
Fork tilt up
Frame tilt or
sway right
Frame tilt or
sway left

SAFE OPERATION
59
Caution
 Keep both feet, arms and legs inside the
protection of the ROPS cab
 Right foot accelerate,
 Left foot brake pedal, cover the brake when
traveling
 Telehandler - Frame tilt is for leveling the
forklift ONLY!
 Telehandler - Keep the forklift level at ZERO
when traveling and before lifting.
 Telehandler - DO NOT FRAME TILT once
boom is raised.

SAFE OPERATION
60
Starting
 Get into the seat with three points of contact
 Adjust the seat
 Fasten your seat belt, adjust it tight across your lap
–Electric or Hand Parking Brake must be set, ON for forklift to
start
–Transmission selector must be in NEUTRAL for the
forklift to start
–Put your left foot on the brake when starting.
–Turn the key
–DANGER!!! Never start any equipment without sitting
in the seat.
–Keep all body parts including hands and feet inside the
cab
Starting – Left foot brake, gear
selector in neutral, parking brake set,
turn the key

SAFE OPERATION
61
Example:
A cube of concrete block weighs about 3,000 lbs.
note GREEN bounded area of safe capacity
What are the Limits:
 Fly Boom #6 showing, 50 degrees
 Fly Boom #3 showing, OK
Distance in feet
in front of the tires
Height Range in feet
Boom angle
indicator, in degrees
Numbers or letters
on fly boom
sections, indicate
distance fly boom is
extended
3,000 lbs.
JLG G6-42
Range of capacity
in pounds

SAFE OPERATION
62
Test:
What are the limits on this load chart for an
8k capacity forklift when carrying 3,000 lbs.?
Answers:
 E – 40 degrees
 D – 35 degrees
 C – OK
3,000 lbs.
35°
Skytrak 8042

SAFE OPERATION
63
Capacity Limits
Reading the Fly Boom Letters or
Numbers and Boom Angle Indicator
tells the operator where they are
on the load chart and therefore
the capacity

SAFE OPERATION
64
Overloaded outside
load chart capacity

SAFE OPERATION
65
35 degrees on boom angle indicator.
Genie, Square Shooter, Terex 644C

SAFE OPERATION
66
Cube of block = 3,000 lbs., letter C
on fly boom, 35 degrees on boom
angle indicator, was crossing over
to the 2,000 lb. capacity
when boom broke.
NOTE: 35° 27’ height and 22’ reach in front
for cube of block or 3,000 lbs.
Cube of block
27’ – 44’
Genie, Terex, Square
Shooter GTH-644C

SAFE OPERATION
67
Oscillating Axle
Unlocked
Stability Triangle
Oscillating Axles (Telehandlers)
 The rear axle oscillates over rough uneven terrain
 Rear oscillating axle locks when the lift is stopped and
at certain height angles and/or boom length
 Once axle locks you should not drive the lift
 The locked rear oscillating axle creates a stability rectangle that is
 Dependent on all four tires being on FIRM, FLAT,
LEVEL GROUND
Oscillating
Axle Locked
Stability
Rectangle
If you were to drive when the oscillating axle is locked and one tire was on
unstable ground the lift could tip over

SAFE OPERATION
68
24”
Load Center
48 Inch
Forks
Load Center
Unknown Zone
Unknown Zone
Load Center
 Most forklifts are designed and tested to
a 24-inch load center
 Designed to pick up a 48” x 48” x 48” cube
with the load laterally centered
 Stick and brick demonstration
 ALWAYS put the forks all the way into the
pallet or load

SAFE OPERATION
The math*
 Weight of load
 Multiplied by New Load Center
 Divided by Rated Load Center =
 New weight
4000 lbs. x 36” / 24” = 6,000 lbs.
*Recommendations from JLG. Other manufacturers
may be different.
24”
36”
6,000 lbs.
4,000 lbs.
Improperly distributed loads may tip the
forklift if the operator exceeds the stated
capacity of the truck.

SAFE OPERATION
–24 in. load center 5,000 lbs. rated
capacity, new load center of 28” =
 5,833 lbs. (equivalent load calculation)
–24 in. load center 4,000 lbs. rated
capacity, new load center of 36”=
 6,000 (equivalent load calculation)
Equivalent Load Calculation
Get your calculators out, do the math:

SAFE OPERATION
71
JLG, SkyTrak has
shackle & Load
Chart for lifting
To Avoid Vehicle Tip
over ALWAYS:
 Travel Slowly
 Rig Properly
 Use Two Tethers
Suspended Loads
 It is not recommended to suspend a load from a forklift
due to risk of
–Tip-over
–Hitting something or someone
 If you do,
–Place sling at or behind 24 inches from rear of forks with
an approved attachment
–Use an OEM approved attachment
–Tether the load, so it does not spin or swing
–Keep boom as low as possible
–DO NOT TRAVEL with the boom raised, as this is
extremely dangerous and can cause tip-over

SAFE OPERATION
72
Steel Ball on a String
Stability
 Constant changing
 Tilting the forks/mast forward
 Tilting the forks/mast back
 Driving – Speed
 Steering, especially with mast or
boom raised
 Center of Gravity changes
 Forklifts become more stable with a load and can be
unstable without a load

SAFE OPERATION
73
Stability
Straight mast at rest no load

SAFE OPERATION
74
Stability
 Straight mast
 Mast raised with load

SAFE OPERATION
75
Stability
 Variable Reach
 Without Load
 Least Stable

SAFE OPERATION
76
Stability Without
a Load
Variable Reach
Rear of
Stability
Triangle
Center of Gravity
 Boom up
 No load
 Least stable
NOTE: Stability
Triangle is Turned
Upward for illustration
purposes ONLY

SAFE OPERATION
77
Rear of
Stability
Triangle
Center of Gravity
 Boom up
 With load
 More stable
NOTE: Stability
Triangle is Turned
Upward for illustration
purposes ONLY
Stability With
a Load
Variable Reach

SAFE OPERATION
78
Rear of
Stability
Triangle
Center of Gravity
 Outside Stability Triangle
 Boom up
 No load, after load deposit
 Least stable
Stability
Variable Reach on Slope

SAFE OPERATION
79
Rear of
Stability
Triangle is
very narrow
Center of Gravity
 Boom up
 No load
 Least stable
Stability
Variable Reach

SAFE OPERATION
80
Center of Gravity
 Boom up
 No load
 Least stable
 Level the machine
Rear of Stability
Triangle
is very narrow
When Center of
Gravity moves
outside this area
forklift will tip.
Stability
Variable Reach

SAFE OPERATION
81
No Load
Counterweight
Driving Without
a Load
 Always keep load (counterweight) above
your head, when no load on forks
 This would be the correct way to load
the forklift onto a trailer
 When the load obstructs your vision use
a spotter

SAFE OPERATION
82
Driving With a Load
 Always keep load above your
head, up hill
 When the load obstructs your vision use a
spotter

SAFE OPERATION
83
Reasons for Forklift Tip-over
 Overloading Do Not Overload
 Sudden Turns Smooth Turns
 Sudden Acceleration Smooth Acceleration
 Sudden Stops Smooth Braking
 Not Level Keep Level
 Frame Tilt with Load Keep Level
 Slopes Keep Level
 Swinging Loads Smooth Operation
The further the center of gravity moves to the rear the less range it has to
move across or side to side and remain inside the stability triangle

SAFE OPERATION
84
Seatbelt
 Required to wear seat belt in forklifts to:
–Prevent you from falling out of seat if a
tip-over occurs
–Keep you within the protection of the
ROPS
–Keep you from getting up and wanting
to get out
Should the machine start to tip over, grasp the steering wheel tightly to keep
both hands inside the ROPS canopy and lean away from the point of impact.
NEVER attempt to jump clear. Should you attempt to jump clear, you could
be injured or killed.

SAFE OPERATION
85
Forklift Stability
 Keep these points in mind:
–Keep boom/forks/load low
–Cradle load
–Slow machine down
–Accelerate and brake gently
–Level the forklift or reposition
–Do not frame tilt with boom raised
–Telehandler - Boom and Telescope the load
never drive the load in or out

SAFE OPERATION
86
What does the load weigh?
 Calculating Pallet Loads
 Do the math
8 rows x 8 bags/row = 64 bags.
64 bags x 50 lbs. = 3,200 lbs.

SAFE OPERATION
87
What does the load weigh?
 Bill of Lading
 Package Labels
 ID plate on equipment
 Ask your supervisor
 Operators must know the weight of
the load

SAFE OPERATION
88
 Adjusting
Telehandler
Forks

SAFE OPERATION
89
Steering
 Two-wheel front steer
 Four-wheel (be aware of rear swing)
 Crab/ Oblique
–Should only be used to get into or out of
tight spots
 Always realign the steering to the
straight position before changing the
steer selector
Large Blind Spot

SAFE OPERATION
90
Blind Spots
Raise Boom enough to see your
Right Mirror
Large Blind Spot

SAFE OPERATION
91
Before Load Deposit
 Do not use broken pallets
 Set forks as wide as possible
 Loads shall be centered
 Cradle the load by tilting the forks back
 Never put boom/load over people
 Be certain landing point can support the load
 Landing should be level
 Make sure path is clear
 Stop the machine and set parking brake
 Place in neutral, do not drive the load in (except straight mast)
 Level forklift
 Then raise the boom/load to the landing point

SAFE OPERATION
92
Load Deposit and After
 Never put boom/load over people
 Raise load and place carefully
 Observe landing
 Tilt forks forward to land the load
 After load is placed, center of gravity changes
 Extract forks with boom do not drive the forks out (except
straight mast)
 Verify lower path clear
 Retract and lower boom/forks
 Look around before travel
 When stacking be sure stack is stable

SAFE OPERATION
 Picking
 Placing the
load
93

 ___ forks back to cradle the load, ___ forks forward
to land the load.
 Oblique or crab steer should only be used when
trying to get into or out of tight spots.
True False
 Before you can lift a load, you must know the
______ of what you are picking up.
 Keep the _____ and _____ low while traveling.
 It does not matter what type of fuel a forklift takes.
TRUE FALSE
 A Danger label means immediate hazards which
___ result in severe personal injury or death.
 _________ must be on the machine and ______
must be legible.
Tilt tilt
weight
boom mast
SAFE OPERATION, GEAR QUIZ
94
will
labels
Manuals
11

WHAT CAN GO WRONG?
22
Soft soil and sloped
terrain, driving with the
boom raised

WHAT CAN GO WRONG?
 Traveling with load extended
 Overloaded per the load chart
97

WHAT CAN GO WRONG?
98
Overloaded

WHAT CAN GO WRONG?
99
-Driving while
boom elevated
- Man basket

WHAT CAN GO WRONG?
100
NEVER
Un-Level a
forklift lift.
This could
result in a
Tip-Over!

WHAT CAN GO WRONG?
101
Driving while
boom elevated.
Contact Power Line

WHAT CAN GO WRONG?
102
NOTE: Water from the water
filled tires when they blew.
Driving while
boom elevated.
Contact Power Line
NOTE: Water from the water filled
tires when they blew

WHAT CAN GO WRONG?
103
Accidents
 Four-wheel drive?
 Always check surface support
 Forklifts are very heavy
 Rough Terrain Telehandlers range in weight
from 16,000 lbs. to 36,000 lbs. without a load

WHAT CAN GO WRONG?
104
Accidents
 Overloaded
 Not checking load chart
 Untrained
 Never lift load over people

WHAT CAN GO WRONG?
105
Accidents
 Lifting
personnel or
climbing up
the
mast/boom is
not allowed.

WHAT CAN GO WRONG?
106
Tried to nudge a tilt-up wall.

What can go wrong, GEAR QUIZ
107
1. Can the _______ the forklift is to be operated on support the
forklift and its load?
2. Stay at least ______ away from overhead power lines
including materials being handled on the forklift.
3. OSHA requires you to ___________ truck/trailer wheels
against the loading dock.
surface
20 feet
wheel chock
13

PARKING &
SHUT DOWN

SHUTTING DOWN
109
Always park on level surface or chock wheels, stabilizers down
Lower forks/boom/mast to the ground, point forks down
Neutralize Neutralize controls, transmission selector in Neutral
Set parking brake
Idle engine
Shut off key switch
Move hydraulic controls
Unfasten seatbelt
Dismount properly
Chock wheels
Lock any anti-vandalism
Refuel
Point the forks down when parked.
Remove key
15

SUMMARY
110
Complete the test, we will go outside for the
hands-on portion after going over the test.
Introductions
Training Objectives
Types of Equipment
Pre-Start Inspection
Safe Operation
What Can Go Wrong?
Parking & Shut Down
Test
Summary
Hands-On Assessment

TEST

TEST
112
1. A hazard label that reads "DANGER" means:
A. Hazards or unsafe
practices that could result
in severe personal injury
or death
B. Immediate hazards which
will result in severe
personal injury or death
C. Immediate hazards which
could result in severe
personal injury or death
D. Be careful
2. A pre-start inspection is done:
A. Before the start of the day
B. Before the start of the
work shift
C. Every time I get on
the forklift
D. Either A or B
3. A pre-start inspection does NOT include:
A. Checking the oil
B. Inspecting soil conditions
C. Reviewing operator manual
D. ROPS
4. If the seat belt is not operating properly, do not use the
forklift and report the defect to your supervisor.
True False
5. It is a “Best Practice” to stay at least:
A. 5 feet away from
power lines
B. 10 feet away from
power lines
C. 20 feet away from
power lines
D. 50 feet away from
power lines
Continue

TEST
113
6. Frame tilt on a rough terrain telehandler (reach) forklift
is used to:
A. Put the forklift out of
level to place loads off
to the side
B. Keep the forklift level at all
times over un-level ground
C. Level the forklift before
lifting the boom
D. B and C
7. What are the considerations when getting off the forklift
to adjust the forks?
A. Shift to neutral
B. Set parking brake
C. Three points of contact
D. All the above and more
8. As a trained forklift operator, I should know the weight
of the load I am picking up.
True False
9. The forklift load chart shows a rating of 6000 lb. at a
24-inch load center. What does this mean?
A. That the forklift will safely
lift any weight up to 6000 lb.
B. That the forklift will safely lift
up to 6000 lb. provided that
the center of gravity of the
load is not more than 24
inches forward from the face
(heel) of the forks
C. That the forklift will only
safely lift up to 6000 lb. if the
load measures more than 48
inches in length
D. That the forklift will lift
more than 6000 lb. if the
load's center is at 24 inches
or fewer
10. What procedure do you follow when the load on the front
of your forklift obscures your view?
A. Dismount, check that the
way is clear and then drive
slowly forward, sounding
the horn
B. Travel in reverse, looking
in the direction of travel
and use a spotter
C. Raise the load so that you
can see under it
D. Sound the horn as you
travel forward
Continue

TEST
114
Continue
11. A small hydraulic leak develops while you are operating
the forklift, you should:
A. Ignore and report it to
your supervisor at the end
of the day
B. Park the forklift in a safe
place and shut it down.
Take the key out and
red tag it, then tell your
supervisor about the leak
C. Keep working until you see your
supervisor and then tell them
D. Stop immediately where you are
and shut down
the forklift
12. “Three points of contact” describes:
A. The forks as they go into
the pallet
B. The stability triangle
C. That three tires must be on
the ground to lift a load
D. The proper way to get on
and get off a forklift when
getting into the cab or seat
13. The seat belt:
A. Is only used when the
boss is around
B. Does not need to be tight
across my lap
C. Needs to be connected
tightly around my lap at
all times while I am
operating the forklift
D. Should be disconnected if
the forklift begins to tip
14. When operating a Telehandler forklift, what position
should the forks be in while traveling?
A. As near the ground as
possible, with the boom
only high enough to see
the right-side mirror
B. It does not matter
C. 12 inches off the ground
D. 4 feet off the ground
15. Who is responsible for the safety of people working
around the forklift?
A. Each person in your area
B. You, the forklift operator
C. The general contractor

TEST
115
Continue
16. Cradling the load means:
A. Tilting the forks back
with the load so the
load is secure against
the backrest
B. Making sure the load is
secure on the pallet
C. Making sure the pallet is in
good condition
17. When driving a loaded forklift down a slope, in what
direction should the forks point?
A. Downhill B. Uphill
18. Attachments other than the stock forks or the forks
designated on the ID plate:
A. Are never allowed
B. Are allowed when your
supervisor says so
C. Are allowed only
if authorized by
the manufacturer
19. When driving forward and steering a four-wheel steer
telehandler forklift, you must always:
A. Look in the direction
of travel
B. Look in the direction of
travel and the path of the
rear steer tires
C. Look backwards
D. Check your mirrors
20. If a load shifts or falls off the forks, you should:
A. Immediately get off the
forklift and put the load
back on the forks
B. Shut the forklift down and
get off the forklift to adjust
the load
C. Shut the forklift down and
get off the forklift to adjust
the load, get help if needed
and report the incident to
your supervisor
D. Get off the forklift while it is
running, adjust the load
and get back on before
someone sees you
21. Is it permissible for any person to operate a forklift?
A. Only if they have a
driver’s license
B. Only if they are trained
and authorized to do so
C. Yes, but only temporarily

TEST
116
Continue
22. When is it allowable to drive your telehandler with its
load fully raised?
A. Any time
B. When placing or picking
the load at height
C. Never
D. When my supervisors
says it is OK
23. When approaching a blind corner:
A. You should slow down
B. You should slow down,
sound your horn and
proceed with caution,
spotter or traffic control
may be required
C. You should stop, get off
the forklift
24. The operating manual for the specific make and model
forklift should be on the forklift when it is being operated.
True False
25. Which of the points below affect the stability of a forklift?
A. Driving too fast
B. Load too heavy
C. Driving on an incline
D. Cornering too sharply
E. All the above
26. A 6,000 lb. rated telehandler (JLG 6042) weighs about:
A. 10,000 lb.
B. 6,000 lb.
C. 22,000 lb.
D. 8,000 lb.
27. The most serious and common forklift accident is:
A. Tip-over
B. Material striking the forklift
C. A worker falling from
the forklift
D. A worker injured during
forklift repair
28. The load charts for telehandlers are all the same.
True False

TEST
117
29. The load chart tells you how much the load weighs.
True False
30. When traveling:
A. Make sure your path is clear
B. Use your mirrors
C. Use the Collision Avoidance
backup sensors
D. Use a spotter if your vision
is obscured
E. All of the above
31. To accurately use the capacity chart, the operator must
first determine three important things:
A. Weight of the load
being lifted
B. Height of the structure where
the load is to be placed
C. Distance where the load will
ultimately be placed in front of
the front tires
D. All of the above
32. On most telehandlers, you shift gears:
A. On the floor
B. On the transmission selector
C. On the transmission selector,
by rotating the twist grip
D. By pressing on the
accelerator pedal
34. On telehandlers with electric parking brakes:
A. The brake must be set to ON
in order for the forklift to start
B. The brake must be set to
ON before leaving the seat
of the forklift
C. The brake does affect starting
the forklift
D. All the above
33. You should always use the frame tilt (sway) lever to level
the telehandler before raising the boom above horizontal.
True False
35. Refer to the JLG G6-42 load chart (Chart I). If the load is
3,000 lb. and you have to place it at 20 feet of height and
cannot get the forklift closer than 20 feet, can this forklift
make the lift?
Yes No
36. Refer to the Skytrack 10054 load chart (Chart IIb). What
does the symbol below the grey circle with the
exclamation point represent?
A. Outriggers
B. Outriggers must be
down in this load range
C. Outriggers must be up
in this load range
D. Outriggers are not required
in this load rangeContinue

TEST
118
37. Refer to the JLG G6-42 load chart (Chart I). If load has to be
landed at 20 feet of height and you cannot get the forklift
closer than 20 feet to the structure, what is the maximum
weight that can be placed at that height and distance?
A. 1,000 lb.
B. 3,000 lb.
C. 6,000 lb.
D. 2,000 lb.
38. Refer to the Skytrak 10054 load chart (Chart IIa). The
numbers A, B, C, D, E, F, G and H indicate:
A. The distance the forklift
can reach
B. The distance the load can
be landed or picked
C. The point of boom extension
and they correspond to on
the load capacity chart
D. The point of boom extension
as it corresponds to the load
capacity chart and is used
along with the boom angle
indicator to determine if a
load can be placed at a
specific height and distance
39. Refer to the Skytrak 10054 load chart (Chart IIb). If the
load is 3,000 lb. what is the maximum distance in front of
the tires that you can place the load with the outriggers
up?
A. 10 feet
B. 30 feet
C. 25 feet
D. 20 feet
40. Refer to the Skytrak 10054 load chart (Chart IIa). If the
load is 4,000 lb. what is the maximum distance you can
place the load in front of the tires with outriggers down?
A. 10 feet
B. 31 feet
C. 26 feet
D. 20 feet
Once complete, gather up your belongings and
let’s head out to conduct the Hand-On Evaluations

HANDS-ON
ASSESSMENT

HANDS-ON EVALUATION
120
Description of Action Completed NA
Pre-Start Checks
Checks Engine and Oil
Checks Hydraulics
Checks ROPS/FOPS
Checks Carriage and Attachment
Points
Checks All I.D. Plates
Checks Tires
Checks Forks
Checks Seat Belt
Start Up
Gets on Forklift Properly
Puts On and Adjusts Seatbelt
Sets Parking Brake
Sets Controls to Neutral
Sounds and Checks for Horns
Checks for Personnel
Starts Engine
Performs Function Checks
Operation
Accelerates Smoothly
Limits Speeds to Conditions
Turning
Slows Before Turns
Considers Balance
Stays Within Lines
Careful of Turning Radius
Stopping
Slows Down
Comes to a Full Stop
Sets Parking Brake
Load Pick Up
Aligns Forklift with Road
Approaches Slowly
Applies Parking Brake
Stops Prior to Load
Makes Final Adjustments
Positions Fork Under Load
Lifts Load Slowly
Cradles Load
Releases Parking Brake
Backs off Slowly
Lowers Fork Immediately
Checks Load Stability

HANDS-ON EVALUATION
121
Transport
Accelerates Slowly
Keeps Load Low
Frequently Scans Area
Decelerates for Turns
Exercises Caution on Hills
Handles Ascent Properly
Handles Descent Properly
Sets Parking Brake
Load Deposit
Aligns Fork with Landing
Approaches Slowly
Applies Parking Brake
Stops Prior to Landing
Makes Final Adjustments
Positions Load Above Landing
Levels Load
Deposits Load Slowly
Backs Off Slowly
Checks Load Stability
Forklift Shutdown
Parks on Level Surface
Sets Parking Brake
Sets Controls to Neutral
Turns Off Engine
Exits Machine Correctly

HANDS-ON OBJECTIVES
Common Mistakes
122
Fork tilt to cradle
load
Always put the
forks all the way
into pallet
Always maintain
3-point contact
getting on and
off
Look back
before
backing up,
use your
mirrors
Use horn

HANDS-ON OBJECTIVES
Common Mistakes
123
Set the parking
brake,
telehandler
DO NOT DRIVE to
place or pick the
load (telehandler)
use the boom
joystick to boom in
and out of the load
Run the RPM’s up
to 2500 RPM’s to
operate fork/boom
controls with your
right foot
Left-foot brake,
Right foot
accelerate
Shift to neutral
when stopped

HANDS-ON OBJECTIVES
124
This will not make you a
forklift operator
 Only hours of operation will
 Develop good habits
 Dispel bad habits
 Each forklift is different
–Read operator’s manuals
–Study ID plates/load charts

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