Unit COFL01- Forklift

Operator Training

Learning Manual

Name Friel JOEL Year

Course Forklift Machine Operator 2023
Unit COFL01- Forklift Operator Training
Course Objective and Outcomes

Objectives
In this course you will learn how to;
 Do pre-start checks/inspections
 Do operational checks
 Identify different safety features (Machine & Personal)
 Identify hazards (Machine & Personal)
 Identify SWL (Safe Working Load)
 Handle hazardous materials
 Drive/operate Forklift safely
 Identify load Centre
 Stock/unstock load(s) safely
 Apply OH&S(Occupational health & Safety) Rules and procedures

Outcomes
At the completion of the training sessions, the participants should be able to;
 State the major causes of Forklift accident
 State factor which contribute to Forklift accident
 List 10 pre- Operational Forklift check
 Explain how to determine safe working load of Forklift
 Identify what can and cannot lift on a Forklift
 Name the major causes of Liberal and Longitudinal instability
 Describe the “Load Centre “
 State safe operating procedures for stacking loads
 Name a operational Rules

Course Aim &Target Group

Aim:
This course is purposely designed to provide equip trainees with knowledge and skills to operate the
Forklift safely with an improved attitude and to be assessed for licensing.

Target Group:
Generally all working class people operating in and around construction sites, mining and
non-mining industries including warehousing, freight and cargo handlers etc.
People in both formal and informal employment with driving experience but not undergone a
certified training programs are encourage to attend this training as well.

Course Topic/Units

Safety
Machines and personal safety, safety decals,
starting, moving and operating safety
Emergency shut -down procedures

Maintenance Inspections
Walk-around inspection
Lower ground checks,
Upper deck, cabin and engine compartment checks
All fluid level and conditions checks,
Operational checks,
Start engine and check all control and functions

Electrical Monitoring System

Identifying universal symbols and signs
Identify and apply three warning categories and procedures
Identify difference in warning lamb and warning buzzer
Identify types of gauges and it’s functions

Lever and control Familiarization

Identify types of controls and their functions
Correctly applying the control when required
Identify types of brakes and their functions

Operational Techniques
Identify and apply safe operating technique
Identify correct application for certain task
Identify correct stacking procedures

Application
Identify the correct machine types for certain types and conditions,
Identify and plan task,
Identify the best stacking cycle with the forks,
Identify the Forks lift safe procedures when, picking up load, setting down a load, traveling with or
without a load and safe parking
procedures.
FORKLIFT SAFETY FEATURES AND CONTROL

Transmission control lever FUNCTION and DIRECTIONS

1.Push lever-to go Forward

2.Centre Position – is Neutral
3.Pull lever- To Reverse/go Backwards
Forklift Operational PEDALS and their Functions

FUNCTIONS
1.Operation (Clutch) Brake PEDAL operate and act as a clutch to disengage and engage the drive only
from to the transmission. It does not play the role of service-brake that grips the wheel brake drums
when applied. The forklift can still move if it’s operating on an incline/stop.

2.Service Brake PADEL is the actual Brake that grips the wheel brake-drums when applied to stop
the forklift from moving, even if it’s operating on an incline/stop.

3.Acccelerator PEDAL is for speeding the machine/forklift when traveling and also speed up it’s
hydraulic operational Functions like raising or lifting, tilting and side-shifting forks.
HYDRAULIC CONTROLS

Directions and Functions of each lever

1.Lift Control lever- Pull lever towards you to raise the fork
Push lever forward to lower the forks(Pull Up- Push down)

2.Tilt control lever- pull lever towards you to bring the forks and mast closer to the forklift
Push lever forward to tilt the fork and mast away from the forklift.
(Pull back- Push forward)

3.Side shift control lever- pull lever towards you to bring the forks towards left hand side
Push lever forward to bring the forks towards Right Hand side.
(Pull Right – Push Left)

Note
Remember, the three hydraulic levers functional DIRECTIONS; Pull and Push only.
FORKLIFT SAFETY FEATURES AND CONTROLS

Light Switch Lever/Control

FUNCTIONS and DIRECTIONS
1.PUSH lever forward -for left signal indicator
2.Centre Position -is OFF
3.Pull lever back- for Right signal indicator
4.Fist Turn – for park light
5.Second Turn- For Head/work light
WORDS INITIALS AND DEFINITIONS

WORDS DEFINITIONS
SAFETY SAFETY – comes from the word, safe, means to secure, protected, sheltered, guarded,
unharmed, uninjured, All Right, well and so on etc.
HAZARD HAZARD is defined as “POTENTAIL DANGER” something that is potentially dangerous.
Danger Threat, Risk, Peril and Menace
PRE-(Start) PRE means: First of all(before starting the engine) to do or check certain things prior to
starting engine etc.
STACKING Means: to heap or piles up loads(as pyramid) mountain.
FEATURES Means: characteristics, attributes, quality or property/items the machine have on it etc.
ROP/FOP Means: Roll Over Protection or Fall Over Protection
OH&S Means: Occupational Health and Safety
JHA Means: Job Hazards Analysis
JSA Means: Job Safety Analysis
STABILITY Comes from the word stable, means; safety, firm, secure and solid etc.
GRAVITY Means: seriousness, importance, consequence of situations. In this case The “LOAD
Centre” Where the weight of the load is concentrated at weight concentration area
point
PPE Means: Personal Protective Equipment’s.
DP 25- 70 FORKLIFT

Activity Sheet
Name ten(10) different types of hazards
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

What is Hazards?
Hazard is anything that cause arm, injury or even death to you or your co-workers around you.
Hazard is defined as: Potential Danger, something that is potentially very dangerous, Danger, Threat,
Risk, Peril and Menace.

Therefore, it is always very important to be on alert and also to be able to recognize the different
types of hazards in around your work sites/environment.

Eliminate any hazards where possible by you, otherwise, seek assistance and or report it
immediately to your supervisor if the elimination process is beyond your control.

It is always safe to operate your machine after all the hazards are located and eliminated from your
work sites/environment.
DP25- 70 FORKLIFT

Activity Sheet

Pre-Operational Check
Name five(5) common items to check for when doing operational check
1.
2.
3.
4.
5.

Operation check
Name five(5) common items to check for when doing operational check
1.
2.
3.
4.
5.

Three Hydraulic Check

Identify and name the three(3) hydraulic controls and state their Functions
Name Functions
INSTRUMENT PANEL – OPERATOR CAB

Activity
Write the name of sign/symbol of the arrow pointing to

Note
This instrument panel or Dash Board is taken from a caterpillar Forklift model DP25 and
DP30
SIGNS AND SYMBOLS – OPERATOR’S CAB
COLLAPSED HEIGHT

Forks on ground to top of mast

Maximum Fork Height

From ground to fork when fully raised
FREE LIFT
Height fork can be raised before mast extends.

Safe Working Load (SWL)

Most forklift have two safe working load (SWL) stamped on the load data plate
They are the;
 Mast vertical safe working load
 Mast forward tilt safe working load
Safe working load (SWL) of a forklift is determined by the:
 Weight of load
 Load Centre
 Height of load above ground
 Forward/backwards tilt

Principal of counterbalance Forklift

All the weight behind the point of balance is acting as a counterweight.
SAFETY PERSONAL PROTECTIVE EQUIPMENT (PPE)
OPERATIONAL RULES

 Always travel at the speed permitted as safe and prepare to stop no

matter what surface it is traveling on.
a. Travel @12km/h- stopping distance 7-8m
b. Travel @6km/h- stopping distance 2.9- 3.2m

 Always place load as far back on forks as possible

 Never travel with load elevator more than necessary
 Do not add weight to rear of forklift.
 FORKLIFT TRAINING
Course Outcomes
The aim of this course is to get all the trainees to know, understand and be familiarize with
the safety requirements of the Forklift truck as well as the Operator’s safety before , during
and after operation and be able to perform to the manufacturer standard safety procedures
of the following tasks ;

 Perform pre start check before starting the engine

 Operational check after starting the engine
 Load shifting and stacking procedures
 Parking procedures
All the trainees with or without forklift driving experience should be able to drive it and
perform with ease all the above task at the end of this course and be assessed as
competent.