Complete Forklift Study Guide

Key Components:

• Overhead Guard: Protects operator from falling objects
• Load Backrest: Prevents loads from sliding back toward operator
• Counterweight: Balances load weight to prevent tipping
• Mast: Vertical assembly providing lift
• Carriage: Holds and positions forks
• Capacity Plate: Shows max load weight and load center

Required: At start of each shift

• Check tires for damage and proper inflation
• Verify overhead guard integrity
• Test horn and lights
• Inspect forks for cracks or bends
• Check for fluid leaks
• Test brakes at low speed
• Verify seatbelt functions properly
• Critical: Tag out of service if defects found

Essential Rules:

• Keep forks 4-6 inches off ground when traveling
• Tilt mast back slightly for stability
• Drive forward UP ramps, backward DOWN ramps (with load)
• Slow down for turns, watch rear swing
• Sound horn at intersections and blind spots
• Always wear seatbelt
• If tipping: Stay seated, brace, lean away from fall
• Before leaving: Lower forks, turn off, set brake, remove key

Stability Triangle: Area within two front wheels and rear axle pivot

Load Center: Distance from fork face to load's center of gravity (standard: 24")

• Never exceed rated capacity on data plate
• Insert forks as far as possible (2/3 load length)
• As load center increases, capacity decreases
• Check load is stable before lifting
• Lower load completely before withdrawing forks

• Pedestrians: Yield right-of-way, slow down, sound horn
• Dock edges: Use extreme caution, verify dock plates secure
• Spills: Stop, report, wait for cleanup
• Brake failure: Warn others, use parking brake to stop
• Never: Drive under raised loads, allow passengers, exceed capacity

OSHA Standard 1910.178

• All operators must be trained and certified
• Training required: Classroom + practical hands-on
• Evaluation required every 3 years minimum
• Retraining after accidents or unsafe operation
• Training specific to each forklift type
• Employers must maintain written training records
• Unsafe forklifts must be removed from service