Fork Lift Instructor

APEX TRAINING SERVICES

CONTENTS PAGE PAGE

* Course documentation a framework for instructions 1 * Adjusting programmes to number of trainees 65* Course design - important features 1 * Alternative timetables 66

- 4 days (30 hrs) at 2:1:1 \ for novices* Qualifications of instructors 2 - 3 days(22 hrs) at :1:1

- 3 days (20 hrs) at 3:1:1-Training standards 2 - 2.5 days (16.5 hrs) at 2:1:1 ) for existing operators

- 2 days ( 13 hrs ) at 1 : 1 : 1

* NOVICE OPERATORS - Basic Training 15

- course description - block syllabus .

- detailed syllabus - training programme - timetable

* EXISTING OPERATORS - Basic Training 41 - course description - block syllabus - detailed syllabus - training programme -timetable

* Minimum duration of basic training 64

APEX TRAINING SERVICES

INTRODUCTIONThis trainer’s guide has been produced to interpret the requirements and guidance laid down in the HSC “Approved Code of Practice and Supplementary Guidance” for the Basic Training of Operators of Rider Operated Lift Trucks.

The information contained in the HSC Approved Code of Practice applies in general to all types of Lift Trucks. The more detailed information to be found in this guide, however, applies specifically and exclusively to one truck type namely Counterbalanced industrial lift trucks, rider operated using either ICE or LPG as their power source. For the purpose of this guide the lift trucks detailed are fitted with Fork Arms as the lifting attachment, they being by far the most common used in industry.

Material is included for the training of* novice operators * existing operators.

Novices (i.e. operators wholly without experience of lift trucks or, at best, with no more than a fleeting acquaintance with these machines) will clearly require a course of basic training which differs from that provided for existing operators.

“Existing operators” here is used to describe those operators who, whilst having worked with trucks, have never received satisfactory basic training which has been conducted formally by a qualified lift truck instructor. A course for such individuals will normally be of shorter duration and differ in content, and in style of presentation, from that drawn up for novices.

For both categories, training packages are provided, which have been prepared with the all-important training standards firmly in mind. These standards, set out within, apply to the basic training of operators on all rider operated counterbalanced industrial lift trucks.

For the sake of realism, the packages are based on the use of a particular truck (as identified), and for carrying out specified operations. The training information is not intended to be prescriptive: users are at liberty to amend details wherever the information given is not applicable to their own circumstances. However, there should be no need for significant deviation from the programmes and associated information as set out.

Nor is the content exhaustive in its coverage and maybe expanded to according to local requirements.

It must also be stressed that the information throughout relates to Basic Training only, whether for novice or for existing operators. It is probable that employers’ own in-house training schemes will extend beyond this scope and take account also ofany requisite Specific Job Training and Familiarisation Training. Specific Job Training, will vary depending on the differences in working practices, site layout, loads handled, etc.

Finally an updated practical test of operating skills is included. When conducted by suitably qualified staff, this test will confirm the level of ability of trainees on completion of their basic training. The identical test will be used, for novice or existing operators alike.

On completion of a course of Basic Training for a Lift Truck Operator and the attainment of the standard in the practical test, a “Certificate of Basic Training” will be awarded to the trainee.This does not mean they have fully completed their training programme.

The following information will be clearly stated to the trainees’ employer, or them personally if trained as private individuals.

1. Specific Job Training should take place as defined in the Health and Safety Commission’s Approved Code of Practice and Supplementary Guidance.

2. Familiarisation Training should follow the Specific Training, as defined in the above Code.

3. Upon completion of the above training an Employer should not allow operation of any lift truck, without written authorisation, as defined in the Approved Code.

4. Should operators be required to operate a different type of Lift Truck, or attachment, they must receive additional or conversion training before authorisation is given.

CONCLUSION

The Health and Safety Commission’s Approved Code of Practice and Supplementary Guidance makes it clear that the items, 1 to 4, are essential to ensure that lift truck training is thorough and comprehensive.

It is therefore very important that lift truck instructors bring these requirements to the notice of the employers of lift truck operators or private individuals when arranging training.

APEX TRAINING SERVICES 1

COURSE DOCUMENTATION

an essential framework for instructorsAll successful lift truck instructors will be expected to:

have a thorough and up-to-date knowledge of their subject and environment be highly skilled in operating the truck be adept at applying sound instructional techniques.

It is taken for granted that instructors who use this guide will meet these basicdemands.

COURSE DESIGNimportant features

The overriding consideration in course design is that the minimum training standards, listed at page 3-13, must be met. As part of this process a number of underlying concepts will also be borne in mind, all of which are applicable to any course of basic training for lift truck operators.

These are:- that training must be predominantly practical in nature;- that sufficient “hands on” experience must be given to each

trainee;- that training input (the contribution of the instructor) must be

progressive and logically sequenced;- that sufficient time must be devoted to the all-important driving/

manoeuvring skills prior to moving on to handling loads;- that the maximum acceptable trainee: instructor: truck ratio must

not be exceeded;- that training must be off-the-job, using suitable truck and

facilities;- that trainee performance standards must be verified by practical

testing.

However, for them to make the most effective contribution to a complete course of basic training (whether they are the sole instructor throughout or whether they are sharing with other instructors) there is another, vital factor for them to take into account. All lessons (both practical and theory) will have been carefully designed, for content and for duration etc,. before being put together in a predetermined sequence so as to make up a total course.Each lesson or training period should have its own planned objective, or objectives; if all of these objectives are achieved in turn, then quite obviously the overall aim of the course will have been met.

It follows that instructors should be fully aware of what is expected of them at every point in a course. This is only made possible by them studying the course documentation prepared for their course.

Instructors, therefore, should not begin to prepare their individual lessons plans without first referring carefully to the complete course documentation, which should be readily available to them. Only by making themselves familiar with such basics as the course aim, the syllabus content, the session objectives, the lesson content as described in the programme, and so forth, will they be able to relate each lesson to what will have gone before, to what is to come later, and to know what is required of them during any given lesson.

The two training “packages” which follow are offered as meeting the requisite course documentation. Information such as this invaluable to instructors, because it provides an essential framework or context within which they can prepare each separate period of instruction which they are asked to present.

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QUALIFICATIONS OF INSTRUCTORSAdvice on the selection and training of lift truck instructors is provided in the Health & Safety Commissions Approved Code of Practice & Guidance.

Essentially, however, every instructor intending to teach lift truck operators must be qualified

by being a registered RTITB instructor by being competent to operate whatever truck is to be used when training operators

- by holding the appropriate certificate of basic training- by having any endorsement for the category in use

The first element (i.e. instructor registration) is evidence of a minimum acceptable standard havingBeen achieved in instructional ability, related to lift truck training.

The second is an obvious requirement for the instructor to be capable of operating the truck in accordanceWith the manufacturers handbook and with more than a minimum of expertise.

TRAINING STANDARDSThe following training standards, expressed in terms of competence with associated skills and knowledge for specific topic areas, are considered to be the minimum recognised standards of ability for any certificated operator.

Competence indicate what is expected of a trainee in order to carry out the task.

Associated Skills and Knowledge underpin effective performance.

The standards are the basis on which the training packages in this guide have been developed. The listed competence’s and skills/knowledge will apply equally to novice or existing operators.

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Training StandardsBasic Training of Lift Truck Operators These competences, together with associated skills and

Knowledge will be those expected of any certificated operator Counterbalanced Industrial Fork Lift, Rider Operated. Under the RTITB training arrangements.

Topic Competence’s Skill / Knowledge

Introduction to LiftTruck

* Identify truck type

* Identify main components and explain their basic functions.

Skills* Identify the truck type to be used during training.

* Identify various component parts, to include ( where applicable ):

- Fork arms - these are the attachments used in the two courses. They could be:- Clamps- Forks- Rotators- Buckets- Fork arms carrier or carriage plate securing pins and stop bolts- Backrest- Mast- Chains- Lift cylinders- Tilt mechanism- Counterbalance weight- Hydraulic oil tank- Battery compartment- Starter Battery- Filler caps- Rear load wheels- Front load wheels- Capacity plate- Overhead guard- Load guard

3Topic Competence’s Skill/Knowledge

Controls and Instruments * Identify all hand and foot operated controls, and instruments.

* Explain their function.

Knowledge

* Understand the main uses of a lift truck.

* Understand the counterbalanced principles as applicable to the truck to be used during training.

* Understand the function of the main parts of the truck (excluding instruments and driving/operating controls.

Skills

* Identify various controls and Instruments, to include (where applicable):

- Seat adjusters- Seat belt- Steering wheel and assistor- Parking brake lever- Footbrake pedal- Transmission dump pedal- Gear lever- Two/Four-wheel Drive (where fitted)- Differential Locks- Accelerator pedal- Forward/reverse lever- Horn push- Engine stop control- Ignition switch - Instrument panel- Steering column switch- Indicator control switch- Roof and Rear window wipers- Load indicator

Knowledge

* Understand the functions of truck controls and instruments.4

Topic Competence’s Skill / Knowledge

Starting, Moving &Stopping the truck

* Drive the unladen truck, under control, in a straight line in an unrestricted area and on level ground.

Skills

* Mount and dismount correctly.

* Adjust seat, for position on runners (and height where applicable).

* Start engine/switch on power.

* Select Gear - Direction - Neutral.

* Hold steering wheel correctly.

* Drive under control in both directions.

* Judge position of tips of the fork arms at travelling height.

* Judge position of rearmost part of truck.

* Apply brakes correctly and smoothly.

* Make emergency stop.

* Select safe parking area.

* Stop engine / Switch off power.

Knowledge

* Know the position of the engine stop button appropriate for engine running/cut-off.

* Know safe stopping distances.

* Understand the importance of making all-round visual checks before setting off, of looking in the direction of travel, and checking for overhead clearance of mast.

* Understand the importance of selecting parking place with care.

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Topic Competence Skills/Knowledge

Starting, Moving &Stopping the truck(continued)

Knowledge (continued)

* Understanding the importance of making the truck safe before dismounting.

* Understanding the importance of making visual safety checks before dismounting.

* Understanding the importance of keeping limbs within the truck confines during travel.

Steering * Steer the truck, Laden & Unladen, forwards and in reverse.

* Position the truck accurately in relation to obstacles & loads.

Skills

* Use steering assistor correctly, with either hand.

* Drive forwards and in reverse parallel to, & in close proximity to, a vertical face at either side of the truck or load.

* Judge when pivot point is aligned with object to be turned around/approach.

* Relate the amount of steering lock to the radius of the arc described by the actual and potential outermost points of the truck and/or load.

* Check visually for rear and front end swing.

Knowledge

* Understand the effects of speed, acceleration & sharp cornering on stability of the truck & security of load.

* Know the correct line of approach & position of a truck for a 90º stacking/de-stacking.

* Know the correct line of approach for loading/unloading road vehicles from ground level.

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Topic Competence’s Skills/Knowledge

Hydraulic System * Identify hydraulic components & explain their function.

* Operate hydraulic controls smoothly & correctly.

Skills* Put fork arms in correct position for travel & for parking.

* Adjust mast to a vertical position.

* Apply slight forward & back tilt to mast.

* Control speed of fork arms during lifting & lowering.

* Check for overhead clearances prior to raising mast/fork arms.

* Use controls smoothly & safely.

* Audibly recognise when mast is fully extended.

* Check reservoir levels & top up, when necessary, to manufacturer’s recommended levels & instructions.

Knowledge

* Understand the operating effects of the hydraulic system as applicable to a lift truck.

* Know the names of the various parts of the system.

* Understand the effect of engine speed on lift speed. (ICE truck).

* Understand the importance of releasing lift control lever before mast is fully extended.

* Understand the reasons for operating hydraulic controls (a) from the driving position only & (b) with brake fully applied & truck in neutral.

* Understand the importance of maintaining cleanliness of oil containers & of maintaining manufacturer’s recommended oil levels (possibly affected by the fitting of attachments).

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Lift Truck Stability * Explain the factors which may affect the Skills

stability of the truck.* Read & interpret the manufacturer’s capacity plate.

* Calculate maximum load centre for various loads of regular shape.

* Calculate maximum lift capacity with loads at various centres.

Knowledge

* Understand the see-saw principle as applicable to the Counterbalanced truck.

* Know the factors affecting stability.

* Understand what is meant by “ centre of gravity of load”.

* Understand what is meant by “load centre”.

* Understand that a shortening of rated load centre does not automatically permit an increase in load weight.

* Understand the causes of lateral & longitudinal instability.

* Understand the importance of lifting weights within the actual capacity of the truck.

* Understand the importance of driving a Lift Truck on uneven ground safely.

8Topic Competence’s Skills/Knowledge

Per-use Inspection * Carry out systematic routine inspections of the truck.

Skills

* Complete log book entries. * Carry out pre-use inspection, to include (where applicable):

Check condition of Fork arms, Carriage, Stop bolts, Load back rest, Mast & Rollers, Chains, Wheels ( nuts & rims), Tyres (condition & pressure), Overhead guard, General bodywork.Check - Seat for security & condition.Check all Motive & Hydraulic controls for operation.Check Battery, Oil & Water (including leaks).Check & Replenish as necessary the fuel source - either Diesel or LPG observing all safety /manufacturers recommendations/rules.Check Brakes for efficiency (whilst on the move).Check Horn.Check Steering (whilst on the move).Check all Gauges & Warning lights.

* Record findings in the truck log book.

* Relate findings to given requirements in manufacturers handbook.

Knowledge

* Understand the importance of using only trucks which are in a safe condition.


Weight Assessment * Explain the dangers of overloading & take steps to avoid this unsafe condition.

Skills

* Use the safe load indicator to check the suitability of any load before moving off.

* Recognise when a load is close to maximum safe working load,

(a) - by reference to safe load indicator;(b) - by comparing a marked load weight with known capacity of truck;(c) - by the changes to truck responsive.

Knowledge

* Know the actual lifting capacity of the truck.

* Know the weight of loads frequently.

* Understand the need to lift loads only within the truck’s capacity.

Handling Laden & Unladen pallets * Stack & destack both flat and cornerpost pallets, up to maximum lift height of the truck.

Skills

* Recognise when adjustment required to fork arm spread.

* Spread fork arms to suit individual pallets.

* Line up fork arms with pallet on approach.

* Stop truck with fork tips 100 - 150 mm (4” - 6”) clear of base pallet or racking or scaffolding.

* Adjust tilt of mast & height of fork arms.

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Handling Laden & Unladen pallets(continued)

Skills (continued)

* Drive into pallet fully, Squarely & centrally, avoiding contact between truck & load.

* Check security of the load at point of initial lift.

* Carry pallet/load at correct travel position.

* Select suitable & safe location for stacking.

* Stack pallet/loads at ground level, in required positions & at a spacing of 50-75 mm (2” - 3”).

* Allow room around stacks for manoeuvring truck.

* Stack pallets/load safely onto racking or scaffolding.

* Work within the load limitations of racking/scaffolding sections.

* Stack flat pallets/loads squarely & centrally onto others of identical base dimensions.

* Stack corner-post pallets securely onto similar pallets.

* Recognise when pallets are sufficiently damaged or deformed as to be put aside for repair/disposal.

* Recognise when palletised loads are unsuitable for sacking. & adjust condition of load where possible.

* “ Undercut “ load when necessary.

Knowledge

* Understand the need to adjust position of fork arms to suit pallet dimensions & provide for even spread of weight on forks.

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Handling Laden & Unladen Pallets(continued)

Knowledge (continued)

* Understand the need for extra care when handling metal pallets.

* Know the load limitations of racking/scaffold towers sections.

* Understand the need to limit the height of bulk stacks to avoid crushing goods on the lower panels.

* Understand the importance of preventing pedestrians from passing underneath raised forks.

* Understand the potential effect on stability of undercutting a load.

Driving On/Off up/down Ramps/Gradients.

* Drive laden and unladen truck, under control, on ramps/Gradients.

Skills

* Adjust height and tilt of fork arms for ascending/descending ramps/gradients.

* Select direction of travel for ascending/descending, with laden and unladen truck.

* Control speed of truck.

* Drive in a straight line parallel to, and safe distance from, edge of ramp or Trench/excavations.

Knowledge

* Understand the effects of gradients on truck stability and load security.

* Understand the dangers of turning across a gradient.


Vehicle Loading & Unloading * Load and unload palletised goods over both sides of flat-bed lorry or trailer.

Skills

* Check that flat bed is suitable for loading.

* Check that vehicle is braked/secured against movement prior to loading/unloading.

* Load and unload palletised goods in safe, correct sequence.

* “Gate” loads tightly against headboard and adjacent loads.

* Place counterweights in suitable positions on uncoupled/unsupported semi-trailers prior to loading or completion of unloading.

Knowledge

* Understand the need to prevent upending of uncoupled/’unsupported semi-trailers prior to loading or during unloading.

* Know the safe stacking heights for various loads/post pallets.

Operators Safety Code * Appreciate the need to operate trucks safely and correctly, and to observe the company safety rules.

Knowledge

* Understand the operator safety code.

* Understand the company safety rules.

* Understand the need to operate in conformity with both publications.

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Course DocumentationReminder:

The following course documentation is for guidance.

The syllabus, programmes, etc., covering courses for novice and for existing operators, depict training with an imaginary truck operating with a specified range of loads, pallets and facilities.

Neither of these programmes is intended to be exhaustive in scope or coverage.

With minor adjustments, however, these programmes of basic training would be suitable for the requirements.

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NOVICE OPERATORS

Basic Training

COURSE INFORMATION

Truck: Diesel/ LPG / Electric Counterbalanced Lift Truck, rider-operated.

Trainee Specification: Trainees will have no previous experience of operating lift trucks. Trainees will be over the age of:

- School leaving age for Agriculture and Horticulture.- 18 for the Construction Industry.- 17 for all other operators. They will have a reasonable

degree of physical fitness and be able to satisfy the requirements set out in the guidelines prepared by Employment Medical Advisory Service and in HS(G)6, “Safety in Working with Lift Trucks” produced by HSE. They will also be mentally and physically fit and reasonably intelligent.

Course Aim: On completion of training, trainees will - be able to operate the truck model used during training safely and correctly in accordance with the manufacturer’s handbook and accepted good practice. - clearly understand the causes of instability of truck and loads; - be able to carry out a routine pre-use inspection of the truck.

Trainee: Instructor: truck Ratio: 3: 1 :1:

Duration: 5 days (37.5 hours).15

NOVICE OPERATORSBasic Training

BLOCK SYLLABUS

Diesel /LPG / Electric Counterbalanced Lift Truck, rider-operated

Practical Training 31.5 hrsIntroduction to the lift truck to be used.Controls and instruments.Starting, moving and stopping the truck.Steering the truck.Operation of hydraulic controls.Pre-use inspection and take-over maintenance.Weight assessment.Handling laden and unladen pallets.Driving on/off ramps and inclines.Road vehicle loading and unloading.Stacking/ destacking - free-standing and in racking or scaffolding.

Theory Input 2.25 hrsOperators safety code.Lift truck stability.

Testing 3 hrsPractical test of basic operating skills.Written test of operating knowledge.Practical test of ability to carry out routine pre-use inspection.

Administration 0.75 hr

Total: 37.5 hrs

16NOVICE OPERATORS

Basic Training

DETAILED SYLLABUS

Diesel / LPG / Electric Counterbalanced Lift Truck, rider-operated

Introduction to fork truck e.g. Description of truck type.

SteeringDriving empty and loaded truck, in both forward and reverse directions.

Identification of parts, to include- fork arms, carriage plate, securing pins and stop bolt, backrest, mast, chains, hoist cylinders, tilt mechanism, counterbalance weight, engine compartment, battery, filler caps, rear steering wheels, front load wheels, differential locks (where applicable) capacity plate, over head guard, LPG or Diesel installation

Controls and instrumentsLocation and function of all hand- and foot- operatedcontrols and instruments to include- seat adjustment, steering wheel and assistor, parking brake, foot brake, inching pedal (if fitted) Transmission dump switch or pedal, accelerator, clutch, horn, engine stop button, key switch, hoist and tilt levers, fuel gauge, oil pressure gauge, gear lever, direction control lever, safe load indicator, hour meter.

Starting, moving and stopping the truckCorrect procedure for mounting/dismounting.Procedure for starting/ stopping engine.Selection of gear and direction, including gear changing.Holding steering wheel.Moving off and control of speed in both directions.Stopping, including safe stopping distances, emergency braking and use of parkingbrake.Placing controls in neutral.Height restrictions.

Elementary steering exercises.Difficult manoeuvring exercises

Hydraulic systemThe hydraulic system and its function.Importance of cleanliness of oil containers and of maintaining correct oil level.Identification of main components of hydraulic system.Correct position of mast/fork arms for travel and when parked.Sympathetic and controlled use of hydraulic levers.Judgement of tilt of mast from driving position.

Weight assessmentUse of safe load indicator.Familiarisation with weight of common loads.Methods of dealing with unfamiliar loads, and with loads having offset C of G.

Handling laden and unladen palletsApproach to pallets.Entering and picking up pallets.Setting down pallets and withdrawing truck.Stacking/de-stacking flat pallets, empty and laden.Stacking/de-stacking metal post pallets.Stacking near to a vertical face.Block or free standing stacking.Handling pallets in racking systems/scaffolding.

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Driving on/off rampsDriving up/down ramp with empty truck.Driving up/down ramp with loaded truck.Adjustment of fork arms.Dangers of driving on ramps.

Vehicle loading and unloadingLoading /unloading flat-bed lorry or trailer from either side.Liaison with driver of vehicle.Safety checks prior to loading.

Operators safety codeSafely rules covering inspection and take-over of the truck, driving the truck, stacking/ destacking, load handling in all circumstances, driving on ramps, vehicleloading and unloading, parking the truck, care of the keys and safety aspects(bothgeneral and specific to employer’s premises.)

TestingRTITB Services practical test(s) of basic operating skills.Company practical test of pre-use inspection.Written test of operating knowledge.

Sequence of loading.Position of loads on lorry/trailer.Maximum permitted weight per axle.Maximum load height.Method of “gating” load against headboard and adjacent loads.

Pre-use inspectionImportance of the inspectionsVisual inspection of truck.Reporting defects.Re-fuelling procedures.Checking starter battery and topping up where necessary.Action to be taken when truck faulty.

Fork Truck StabilityExplanation of manufacturer ‘s capacity plate, including load centre.Explanation of see-saw principle as applied to a counterbalanced truck.Explanation of causes of instability (lateral and longitudinal).Explanation of the stabiliser jacks (where applicable).

Course openingWelcome.Introductions.Outline of programme, statement of aim.Outline of training methods.Course administration.

Course closureObtaining trainees’ views on training course.Announcement of results of testing.Outline of certification procedures.Importance of continued safe operating.Need for Specific Job & Familiarisation Training.

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Novice OperatorsBasic Training

DETAILED PROGRAMME AND INSTRUCTORS NOTESDiesel or LPG Counterbalanced Industrial Lift Truck, rider-operated. Ratio 3 trainees: 1 instructor: 1 truck

Day/Session Time Objective/Content Instructor’s Notes Duration Location Aid & Equipment

Day 1: 1 0830-0900 INTRODUCTION TO COURSE Self-explanatory 30 minutes Classroom Copy of timetable for

Day 1: 2 0900-1010

Objective: On completion of this session, trainees will have been introduced to their instructor (and , if necessary, to fellow trainees), will have been advised of the aims of the course and provided with an outline of its content. They will have been made aware of the inclusion of end tests and of the award of certificates to successful trainees.

OPERATORS SAFETY CODE (& film where possible)

Objective: On completion of this session, trainees will have a heightened awareness of the need to operate trucks safely, correctly and skilfully and to follow the company’s safety rules to the letter.

Explain the reasons for, and the benefits of, operator training.

Explain that many accidents occur which may be caused by unskilled operators. Explain briefly that these accidents may range from relatively minor to very serious accidents indeed, and that the results might include injury (or death) to operator or other persons, damage to stock, damage to truck and equipment, to buildings and facilities, or downtime.Use specific examples.

70 minutes Classroom

each trainee.Copy of specimen certificate of basic training.

Copy of company safety guide for each trainee. Copy of operators Safety Code for each trainee.Manufacturer’s handbook for truck to be used in training.Film

19Day/Session Time Objective/Content Instructor’s Notes Duration Location Aid & Equipment

Day 1: 2 continued

Issue company Safety Guide and briefly discuss the major points.

Emphasise that trucks are designed to be perfectly safe, provided that they are not incorrectly used. Point out that there are laid down rules covering operating practices and that this course will concentrate throughout on safe, correct methods.

Ensure that trainees appreciate the need for rules and that the rules published by the company are fully understood. Cover the following points in

particular:

- operators are responsible for carrying out a pre- use check of their truck (detailed information and instruction will be provided later)

- trucks must never be overloaded

-trucks must always be driven and operated by using safe, correct methods (detailed instruction to be given later)

- trucks must always be handled responsibly and with safety as a first priority

- trucks, loads and facilities must never be abused or handled roughly

- keys must always be taken out of unattended trucks.

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Day 1: 2continued

Show a suitable safety film, related to truck operations.

Select the film carefully. Introduce the film, by pointing out that it shows dramatically, what is likely to happen when trucks are not handled correctly and skilfully. Ensure that trainees know in advance why the film is being shown, what to look for and that a discussion will be held immediately afterwards. After showing, encourage trainees, by questioning, to identify

Day 1: 3 1020-1110 INTRODUCTION TO TRUCK, CONTROLS AND INSTRUMENTS

Objective: On completion of this session, trainees will be aware of the main uses of a lift truck, will be able to name the main component parts and explain, in broad terms, their functions

The lift truck - its functions

what they considered to be bad/unsafe practices. (Do not expect, at this stage, technical explanations).

Wind up the entire session by reiterating the need for safety and correct operating practices.

Explain that a truck is a mobile lifting machine, which is highly manoeuvrable. The forks are designed to handle unit loads safely and easily.

50 minutes Training Area

Truck

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Day 1; 3continued

The counterbalance Describe the truck to be used for training - a

diesel-engine or LPG counterbalanced truck. Explain very briefly that weight on the fork arms at one end is counterbalanced by heavy weights built in to the other end. Point out that this truck will be used throughout the course and that the practical test will also be conducted on the same machine.

Identification of parts. Walk round the truck and name the various component parts. Where necessary, and to maintain interest, include a brief description of their function, but remember that at this stage the objective is to give an overall description of the truck, without too much technical detail.

The following should be included:

fork arms, carriage plate, securing pins and stop bolt, load backrest, mast, chains, rollers, hoist cylinders, tilt mechanism, counterbalance weight, engine compartment, battery, filler caps, rear steering wheels, front load wheels, capacity plate, overhead guard, fuel installation- LPG or diesel.

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Day 1: 3continued

Controls and instruments. Turn now to the various hand and foot operated controls, and instruments. Identify each in turn and explain their functions. The following should be included: seat adjustment, steering wheel and assistor, parking brake, foot brake, accelerator, clutch/inching control, transmission dump pedal or switch, horn, engine stop button, key switch,

Day 1: 4 1110-1510 STARTING, MOVING, STEERING AND STOPPING

Objective: On completion of this session, trainees will be able to drive the unladen truck, under control, in both directions and steer accurately round an object.

Mounting and dismounting

Seat adjustment

fuel gauge, oil pressure gauge, gear lever, direction control lever, load indicator, hour meter. Refer also to hoist and tilt levers, stabiliser jacks, but point out that these will be explained later in the course.

Teach the correct method of mounting and dismounting the truck.

Teach how to adjust seat to suit individual requirements.Encourage trainees to adjust seat, if necessary, each time they get on the truck during the course.


Truck. Drums/pallets/ cones.


Day 1: 4continued

Starting and stopping engine

Moving off and stopping (unladen truck)

Teach the method of starting and stopping engine.

Teach how to move off smoothly, in forwards direction and in a straight line. Teach how to stop smoothly. Emphasise the need to check behind and around the truck before moving off, to keep hold of the steering assistor, to look in direction of travel and to control speed. Also to (1) apply parking brake and (2) put controls in

Steering (unladen truck)

neutral when stopped. Emphasise that trainees should always keep their limbs within the confines of the truck when moving. Emphasise also that trainees may only place their heads outside the lines of the truck for alignment purposes after necessary precautions have been taken to ensure that it is safe to do so. Teach how to move in the reverse direction , again in a straight line. Teach how trainees should turn in the seat for comfort and safety/control. Teach emergency stopping. Point out the need to consider the overall height of the truck in relation to any overhead obstructions.

Teach how to steer the truck forwards and in reverse, initially in an area with plenty of space for manoeuvring. Draw attention to the exaggerated rear-end swing and emphasise the need always to pay attention to this. Attention should be drawn to the swing of the forks and the need to regularly check them while steering in reverse.

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Day 1: 4continued

Teach how to pivot, forwards and in reverse, and from both sides of the truck, when steering around a drum or pallet in an open area. Pivot on the easier side first (i.e. left side).

NOTE: As hydraulic controls have not been introduced at this stage, the instructor must

Day 1: 5 1520-1700 SIMPLE MANOEUVRES

Objective: On completion of this session, trainees will be capable of driving an unladen truck, under control, through courses which require greater accuracy in steering and attention to all extremities of the truck.

Simple corners (unladen truck)

Simple manoeuvres (unladen truck)

adjust fork arms and mast prior to take-over by trainees.

Teach how to negotiate 90º turns, left and right, forwards and in reverse, through simple courses.

Progress to slightly more advanced exercises.(N.B. Fork arms set by instructor).

100 minutes Area Truck. Items for constructing a simple course.

Day 2: 1 0830-1110 FURTHER DRIVING

Objective: On completion of the session, trainees will be capable of controlling acceleration, gear changing (where applicable) and completing more difficult manoeuvring exercises with skill and confidence.

150 minutes Area Truck. Items for constructing a simple course.

25


Day 2: 1continued

Day 2: 2 1110-1200

More difficult manoeuvres (unladen truck)

LIFT TRUCK STABILITY

Move on to further manoeuvring exercises, requiring progressively more skill in steering accurately and controlling the truck.

(N.B. Fork arms set by instructor).

50 minutes Classroom or office

Flipchart.Models to illustrate see-

Objective: On completion of this session, trainees will have a clear understanding of the factors which may affect the stability of the truck.

Engineering principles

Working Loads

See-saw principle

Stability

“Load centre”

Explain carefully, but in clear and simple terms, the basic engineering principles of a counterbalanced lift truck.Cover the following points:

- maximum safe working loads (determined by the manufacturer) are indicated on the capacity plate on the truck

- a truck and its load follow the same principles as a see-saw, with the front wheels as the fulcrum and the truck’s counterbalance weight opposing the weight of the load on the fork arms.

- factors affecting stability (changes of speed and direction, weight, load centre, site conditions)

- “load centre” is the distance from the centre of gravity of load to the heel of the forks (calculated with the mast vertical or boon retracted). The manufacturer’s plate will declare the capacities of the truck at specified load centres.

saw principle.

26


Day 2: 2continued

“Load centre” continued

Perfect balance

If the load centre is lengthened, the load-carrying capacity will be reduced. But it does not follow that a shortening of the rated load centre permits an increase in load weight.- perfect balance is a dangerous state and in order to maintain positive stability, the working

Lateral instability

Longitudinal instability

Truck tip over

load indicated on the capacity plate has been arrived at by the manufacturer with due regard to all safety legislation and safe operating practices.- lateral instability may be caused by turning at too high a speed for conditions, turning with raised fork arms and/or load, turning across an incline, operating with a flat or partially deflated tyre, driving one wheel over a bump or pot-hole trench & excavations etc.- longitudinal instability may be caused by overloading the truck, by harsh or indiscriminate use of tilt with a load, by not fully inserting the fork arms, by violent braking or acceleration, by operating incorrectly on ramp or incline, etc.

Point out that, should a truck tip over (laterally or longitudinally), serious or fatal injury can occur if the operator is trapped between the truck and the ground. Emphasise that, should a truck begin to tip over, the operator should:- stay with the truck- hold on firmly- brace feet- lean away from point of impact.

27


Day 2: 3 1200-1250 HYDRAULIC SYSTEM AND USE OF CONTROLS

Objective: On completion at this session, trainees will have a basic understanding of the hydraulic system on a lift truck and will be able to adjust fork arms and mast

50 minutes Area Flip chart.Truck.

correctly for travel and parked positions

Definition

Lift truck hydraulic system

Hygiene and oil levels

Hydraulic controls

Travel and parked positions

Explain that “hydraulics” is the power of a liquid under pressure passed through pipes.

Explain, in simple terms, the operation of the hydraulic system as applied to the fork truck. Name the various parts of the system.

Explain the importance of cleanliness of the oil containers, and of maintaining oil levels in the reservoir at the manufacturer’s recommended level. Caution against overfilling when mast/forks elevated or when attachments have been fitted to the truck.

Teach the operation of the hydraulic controls on the truck. Emphasise smooth and gentle operation. Mention that fork arms may be lowered under control with engine switched off.Explain how engine speed affects speed of lift.

Teach the correct adjustment of mast and fork arms for travel and parked positions.

28


Travel & Parked positions cont’d Emphasise that, for safety reasons, hydraulic controls must only be operated:-- by the operator when sitting in the driving seat.- when the parking brake is fully applied & the directional control/gear lever is in neutral.

Day 2:4 1330-1610 Further Driving, Using Hydraulic Controls.

Objective: On completion of this session, trainees will be further practise in manoeuvring, will be able to adjust fork arms & mast with confidence for correct travel park positions & to negotiate an incline correctly, in both directions, with an unladen truck.

Fork arm travel position

Fork arm park position

On level ground, the normal travel setting for forks is 100 mm (4”) to 150 mm (6”), between the heel of the fork or the lowest point of a pallet/load & the ground with the mast & forks tilted back sufficiently to suit type/stability of load being carried & ground conditions prevailing. Rough or uneven ground may require the clearance between fork heel & the ground, to be increased to suit conditions.

Tilt mast forward & lower fork arms until fork tips contact ground with minimum gap at heel of the fork arms. Do not allow lift chains to lose tension or become slack.

150 mins Area Truck. Items for constructing course.Ramp

29


Day 2: 4Cont’d

Driving exercises (unladen truck) Carry out further difficult manoeuvring exercises, with trainees themselves adjusting fork arms & mast at beginning & end of exercises. Also introduce use of inching pedal/transmission dump pedal (if fitted).

Day 2: 5 1610-1700

Safe parking

Driving on Ramp/Gradient (unladen truck)

Routine Inspection, Take-over & Maintenance

Objective: On completion of this session, trainees will be capable of carrying out a thorough & systematic pre-use inspection (covering the aspects taught), will know how to use the log book correctly, & will be able to refuel the truck.

The importance of routine inspections

Explain what might be considered suitable/unsuitable locations for parking a truck.

Teach the correct method of driving up & down a Ramp/Gradient. Ensure that trainees are fully aware of:

- the need to adjust height of fork arms before & after but not whilst driving on the ramp/gradient.- the need to control speed.- the method of controlling speed.- the line to take whilst on the ramp/gradient (emphasise the dangers of turning across a ramp/gradient)

Explain action if obliged to park on ramp/gradient.

Explain the purpose of carrying out a systematic inspection before using a Counterbalanced Lift Truck.

50 mins Area Truck. Manufacturer’s Handbook. Log book Diesel/LPG. Safety clothing/equipment

30


Day 2: 5Cont’d

Pre-use inspection

NOTE: The list of items to be checked is not finite. The manufacturer’s

Teach the following:

- Check condition of fork arms, carriage, stop bolts, load back rest, mast & rollers, chains,

recommendations for the Counterbalanced lift truck being used must take precedence.This is to ensure no specific item is left unchecked.

Refuelling truck

wheels (nut & rims) tyres (condition, pressures), overhead guard, general bodywork.

- Check seat for security & condition.- Check fuel, battery, oil & water (and for leaks).- Check hydraulic oil level (and for leaks).- Check brakes for efficiency ( whilst on the move).- Check horn.- Check steering (whilst on the move).- Check all gauges & warning lights.

Explain the system of recording findings in the log book provided. Explain laid down procedures when truck is not fit for immediate use & emphasise that no attempt should be made to operate a faulty truck.

Teach how to refuel the truck, i.e. Diesel or LPG observing all safety/manufacturer’s recommendations/rules.

31


Day 3: 1

Day 3: 2

0830-0845

0845-1250

Inspection of Truck

Load Handling

Nominate one trainee to carry out a full routine inspection, and complete log book, prior to today’s training.

15 mins

235 mins

Area

Area

Truck. Log book. Manufacturer’s Handbook.

Truck. Items for

Objective: On completion of this session, trainees will be able to drive an unladen & laden truck in both directions in an open then confined area.

Adjusting spread of fork arms

Picking up/setting down flat pallets.

Manoeuvring with unladen pallet

Picking up/setting down laden pallet.

Teach the method of adjusting spread of fork arms & explain the reasons for making adjustments.

Teach how to pick up & set down correctly an unladen pallet, making a straight-ahead approach. Point out in particular:- Lining up fork arms centrally & squarely with pallet at earliest opportunity.- Allowing correct distance between fork arm tips & pallet before picking up.- How to judge from driving position when mast is at vertical.

Teach how to manoeuvre in difficult situations, taking account of the additional width created by the pallet.

Teach how to pick up & set down a laden pallet, making a straight ahead approach.

constructing course. Various pallets and load.

32


Day 3: 2Cont’d

Manoeuvring with laden pallet Teach how to manoeuvre in difficult situations, taking account of obscured vision resulting from laden pallet on forks. Include driving in both directions through chicanes, Initially not too ‘tight’ but working towards test

Day 3 : 3 1330-1420

Pick up/setting down laden pallet, 90º approach

Stacking/destacking unladen pallets.

Weight Assessment.

Objective: On completion of this session, trainees will clearly understand the effects of overturning the truck & will be able to take steps to avoid this unsafe condition.

Dangers of overloading

Safe load indicator.

dimensions.

Teach how to pick up & set down laden pallets at ground level, making a 90º approach, from both sides but in an open area.

Teach how to stack/destack unladen pallets, making a straight-ahead approach.Teach how to stack/destack unladen pallets, making a 90º approach, from both sides but in an open area.

Reiterate the effects of overloading the truck.

Demonstrate & explain how to interpret the safe load indicator (if fitted).

50 mins Area Truck. Various demonstration load.

33


Day 3 : 3Cont’d

Common loads

Unfamiliar loads.

Familiarise trainees with the weight of loads which they will frequently encounter. Explain how such loads are within the capacity of the truck.

Emphasise the care to be taken when handle

Day 3 : 4 1420-1700 Load Handling (cont’d)

Objective: On completion of this session, trainees will clearly understand the safety & operational requirements of stacking/destacking, will have limited skills in stacking/destacking laden pallets & will be able to drive laden trucks up & down a ramp/gradients.Stacking/destacking laden pallets (straight line approach)

unfamiliar loads.Explain how the ‘feel’ of the truck alters as loads approach near-maximum capacity weights.

Teach how to stack/destack laden pallets, making a straight-line approach, & at various levels. Explain sitting a stack within a agricultural & construction site & the importance of the key pallet.

- Check that the floor is sound & level.- Never stack against a wall or doorway.- Never obscure fire extinguishers, alarm points of emergency exits/assembly points.Explain the factors to be considered when stacking:- Ensure goods on each pallet are secure & levelled of.- Remember the pallet & bottom layer of bottom load must support the weight of the entire stack.- The dangers when stacking too close to an excavation or trench.

150 mins Area Truck. Ramp/gradientsVarious pallets/loads.


Day 3 : 4Cont’d

- Stack close together but allow for forks to protrude if necessary beyond the back of the pallet.- Stack each load squarely & centrally on top of each other.- Leave sufficient room to manoeuvre the

Driving on ramp/gradient/counterbalanced with laden truck.

truck.Teach the correct way of driving up & down a ramp/gradient with a laden pallet.

Day 4 : 1

Day 4 : 2

0830-0845

0845-1250

Inspection of Truck

Load handling (cont’d)

Objective: On completion of this session, trainees will be skilled at stacking/destacking both flat & corner-post pallets.

Stacking/destacking laden pallets (90º approach).

Stacking loads in front of vertical face

Corner-post pallets

Undercutting pallets/loads- All types.

Nominate a different trainee to carry out full routine inspection & complete log book.

Teach the skills of stacking/destacking, making a 90º approach from both sides but in an open area, & at various levels.Repeat this exercise, but approaching in a confined space.Teach how to stack loaded pallets, squarely within 150 mm (6”) of a vertical face.Explain the uses of these types & explain the differences in handling methods.Teach correct procedure on each type of pallet load emphasising the need to stay within the rated capacity of the truck when load centre is extended during under-cutting.

15 mins

235 mins

Area

Area

Truck. Log book. Manufacturer’s Handbook.

Truck. Various loads & pallets.

35


Day 4 : 2Cont’d

Picking up/setting down corner post pallets. Teach how to pick up & set down a corner post pallet at ground level, making a straight line approach & later by making a 90º approach (both sides).Teach how to set down & pick up a corner post

Day 4 : 3 1330-1700

Stacking/destacking corner post pallets.

Vehicle Loading & Unloading

Objective: On completion of this session, trainees will be able to load & unload a flat-bed vehicle from the side.

Safety Checks

pallet close to a vertical face (undercutting if necessary).Teach how to stack/destack corner post pallets, at various levels & between adjoining stacks of other corner post pallets, making a straight line approach.Repeat as above, but making a 90º approach from both sides.Point out that no attempt should be made to stack corner-post pallets on which cupped feet are damaged.

Explain the safety checks & precautions necessary prior to loading/unloading:- Ensure that the vehicle driver is aware of your intentions.

- Ensure that the lorry engine is stopped.

- Ensure that the lorry/trailer has its brake/s set.

- Ensure, before loading, that the loading area is clear of debris & strong enough to withstand the weight of the pallets.

200 mins Area Truck. Flat-bed vehicle. Suitable pallet loads.Wheel chocks.


Day 4 : 3Cont’d

- Avoid placing heavy pallet loads over unsupported parts of semi-trailers, without first taking adequate precautions to prevent upending,- When unloading unsupported semi-trailers, take adequate precautions to preventing upending.

Sequence of loading/unloading

Stacking height

Loading/unloading

Explain, that, wherever possible, vehicles should be loaded starting form the front, working from side to side & distributing the load evenly.Explain the significance of plated axle weights.Unloading should be the reverse of this process.Explain the maximum vehicle stacking heights with company stock or safe height if using corner-post pallets.Teach how to load by “gating against the headboard & adjacent loads, & from both sides.Teach how to unload

Day 5 : 1

Day 5 : 2

0830-0845

0845-1250

Inspection of truck

Load Handling (cont’d)Including Racking/Scaffolding System

Objective: On completion of this session, trainees will have reached test standard in the critical skills, & will also be able to stack & destack pallets in the racking/scaffolding system.

Nominate remaining trainee to carry out a full routine inspection & complete log book.

15 mins Area Truck. Log book.Manufacturer’s Handbook.

Truck. Racking/Scaffolding. Various loads.


Day 5 : 2Cont’d

Stacking/Destacking various pallets.

Advanced Manoeuvring.

Further practice in stacking, destacking various pallets, including bulk stack building.Further practice in driving forwards & backwards through difficult courses with bulky or awkward loads.

Day 5 : 3

Day 5 : 4

Day 5 : 5

Day 5 : 6

1330-1410

1410-1445

BREAK

1500-1645

1645-1700

Racking/Scaffold.

Written Test

Practical Test

- pre-use inspection

Practical Test

- RTITB practical test/s of basic operating skills.

Course Closure

Explain the purpose of the racking/scaffold system.Explain the load limitation of beam sections.Teach how to stack/destack within the racking/scaffold, at various levels, from a straight-line approach & from a 90º approach (both sides, & in “ test conditions”).

Trainees together, with Instructor invigorating.

Individual testing of trainees (others out of sight & hearing).

Carry out test precisely as prescribed from each trainee in turn.Only trainee under test & Instructor/Examiner to be present.

Reiterate the importance of continuing to operate safely & correctly.Issue certificate to successful trainees.

40 mins

35 mins

105 mins

15 mins

Classroom or Office

Area

Test Area

Classroom or Office

Test papers.

Truck. Making sheet clipboard. Manufacturer’s Handbook.

Truck. Test course as laid down. Making sheet as laid down.

Certificate of basic training.

38TIMETABLE

5 Day (37.5 hr) Basic Training Course(3 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric counterbalanced Lift Truck, Rider-operated

Day Classroom Area Area Area Area0830 0900 0900 1010 1020 1110 1110 1250 1330 1510 1520 1700

1Admin.

Outline of CourseOperator’s Safety

Code & FilmIntro. to Truck,

Controls & Instruments

Starting, Moving, Steering & Stopping


Simple Manoeuvring Exercises

Area Area Classroom Area Area Area0830 1010 1020 1110 1110 1200 1200 1250 1330 1510 1520 1610 1610 1700

2General practice

manoeuvring in confined areasFurther driving practice

Lift truck stability

Hydraulic system & use

of controls

Further practiceusing hydraulic controls

Further driving practice

Pre-use Inspection, take-over &

maintenance of Lift Truck

Area Area Area Area0830 1010 1020 1250 1330 1420 1420 1510 1520 1700

3* R.I Load handling - operating

practiceLoad handling - operating practice in open &

confined areas, including pallet handlingLoad weight assessment

Further load handling

Further load handling practice

Area Area Area Area0830 1010 1020 1250 1330 1510 1520 1700

4* R.I Load handling - further

operating practice in confined areas

Load handling - further operating practice in confined areas

Vehicle loading & unloading Vehicle loading & unloading

Area Area Classroom Area Area0830 1010 1020 1250 1330 1410 1410 1445 1500 1645 1700


practice including working with racking/scaffold

Load handling - further practice including working with racking/scaffold

Written Test Test - practical

Inspection

Practical test/s of basic operating skills

Course Closure

* R.I Wherever stated means Routine Inspections, Take-over & Maintenance of the Lift Truck 39

Training should not be restricted to novices. It is equally important that suitabletraining be given to any Existing operators who have not received appropriate basic training, formally conducted by qualified lift truck instructor even though such

operators may never have had an accident.

For its success, their training will be dependanton the use of a carefully devised programme,Which will, of course differ significantly from a novice programme in terms of content, duration etc.In addition, the instructors style of approach will need to be adjusted approprately.

The following documentation will serve as a basis for developing courses relevant tothe requirements of existing, but untrained, operators.

40EXISTING OPERATORSBasic Training

COURSE INFORMATION

Truck: Diesel / LPG / Electric counterbalanced Lift Truck, rider-operated.

Trainee Specification: It is anticipated that trainees attending this coursewill have some previous experience (possibly self-taught) and will befamiliar with the steering characteristics of this machine but will nothave had the benefit of adequate, formal training in basicoperating skills. Trainees will be over the age of:- School leaving age for Agriculture and Horticulture.- 18 for the Construction Industry.- 17 for all other operators. They will have a reasonable degree of physical fitness and be able to satisfy the requirements set out in the guidelines prepared by Employment Medical Advisory Service and in HS(G)6, “Safety in Working with Lift Trucks” produced by

HSE. They will also be mentally and physically fit and reasonably intelligent.

Course Aim: On completion of training, trainees will: - be able to operate the truck model used during training safely and correctly in accordance with the manufacturer’s handbook and accepted good practice. - clearly understand the causes of instability of truck and loads; - be able to carry out a routine pre-use inspection of the truck.

Trainee: Instructor: truck Ratio: 3: 1 :1:

Duration: 20 hour.41

EXISTING OPERATORSBasic Training

BLOCK SYLLABUS

Diesel / LPG / Electric Counterbalanced Lift Truck, rider-operated

Practical Training 15 hrsIntroduction to the lift truck to be used.Controls and instruments.Starting, moving and stopping the truck.Steering the truck.Operation of hydraulic controls.Pre-use inspection and take-over maintenance.Weight assessment.Handling laden and unladen pallets.Driving on/off ramps and inclines.Road vehicle loading and unloading.Stacking/ destacking - free-standing and in racking or scaffolding.

Theory Input 1 hr and 45 min’soperators safety code.Lift truck stability.

Testing 2 hrs and 45 min’sPractical test of basic operating skills.Written test of operating knowledge.Practical test of ability to carry out routine pre-use inspection.

Administration 30 min’s

Total: 20 hrs

42

EXISTING OPERATORS Basic Training

DETAILED SYLLABUSDiesel / LPG / Electric Counterbalanced Lift Truck, rider-operated

Introduction to fork truck e.g. Description of truck type and its function.

Correct naming of parts, to include-fork arms, carriage plate, securing pins and stop bolt, backrest,

mast, chains, lift cylinders, tilt mechanism, hydraulic oil tank, battery, battery lids, rear seat, seat switch, overhead guard,

steering wheel & assistor, parking brake, footbrakeaccelerator, direction lever, horn, hydraulic controls, key switch, rated capacity plate, hour meter, safe load indicator.

Starting, moving and steering the stoppingCorrect procedure for mounting/dismounting.Correct procedure for selecting direction of travel, Holding steering wheel assistor, moving off, controlling speed, Normal And emergency stopping. Height RestrictionsDriving empty truck in forward and reverse directions, progressing from simple to difficult manoeuvres.

Hydraulic systemThe hydraulic system and its function.Importance of reporting leaks, topping up with correct grade of clean fluid.Identification of main components of hydraulic system.Correct position of mast/fork arms when parked and in travel position.Need for sympathetic, smooth operation.Judgement of mast/fork arms position from driving seat.

Battery CareTruck performance determined by efficiency of battery.Battery construction ,Emphasis on Safety RulesDisconnecting truck from batteryMeasuring and recording specific gravityTopping up batteries , Charging ProceeduresTaking Battery off charge Handling laden and unladen palletsCorrect approach entry and pick up.Setting down and withdrawing of fork arms.Correct transportation, stacking and de-stacking of flat pallets,

laden and unladen.Stacking and de-stacking metal corner-post pallets.Stacking close to a vertical face.Block standing, free-standing stacking and stacking/destacking into and out of racking system.Special safety precautions.

Driving on ramps and inclinesCorrect direction, laden and unladen.Height adjustment of fork armsCorrect control of machine, ascending and descending.Special safety precautions.

Vehicle loading and unloadingLoading /unloading flat-bed lorry or over side or tailboard.Safety checks prior to loading.Liaison with vehicles driverSequence of loading.Position of loads on vehicle deckMaximum permitted weight per axle.Maximum load height.Method of “gating” loads Pre-use inspectionImportance of the inspectionIdentification of parts to be inspected.What to look forReporting defects and action in the event of the truck being unsafe.

Lift Truck StabilityExplanation of manufacturer ‘s capacity plate.Explanation of see-saw principle.

Causes of instability (lateral and longitudinal).

Operators safety codeNeed for rulesCurrent accident statisticsExplanation of rules covering take-over of truck, driving, load handling, driving on ramps, building stacks, working in racking, vehicle loading/unloading.Parking Particular safety rules specific to employers premises.

TestingPractical test(s) of basic operating skills.Company practical test of pre-use inspection.Written test of operating knowledge.

Course openingWelcome and introductions.Statement of aim & Outline of programme, Outline of training methods.Course administration.Operators Legal Duties

Feedback and course closureObtaining trainees’ views on training course.Announcement of test resultsOutline of certification procedures.Final stress of importance of continued safe operating.Need for Specific Job & Familiarisation Training.

43

Existing OperatorsBasic Training

DETAILED PROGRAMME AND INSTRUCTORS NOTES

Diesel / LPG / Electric Counterbalanced Lift Truck, rider-operated. Ratio 3 trainees: 1 instructor: 1 truck Day/Session Time Objective/Content Instructor’s Notes Duration Location Aid & Equipment

Day 1: 1

Day 1: 2

0830-0900

0900-1010

INTRODUCTION TO COURSE

Objective: On completion of this session, trainees will have been introduced to their instructor (and , if necessary, to fellow trainees), will have been advised of the aims of the course and provided with an outline of its content. They will have been made aware of the inclusion of end tests and of the award of certificates to successful trainees.

OPERATORS SAFETY CODE (& film where possible)

Objective: On completion of this session, trainees will have a heightened awareness of the need to operate trucks safely, correctly and skilfully and to follow the company’s safety rules to the letter.

Explain the reasons for, and the benefits of, operator training.

Self-explanatory

Explain that many accidents occur which may be caused by unskilled operators. Explain briefly that these accidents may range from relatively minor to very serious accidents indeed, and that the results might include injury (or death) to operator or other persons, damage to stock, damage to truck and equipment, to buildings and facilities, or downtime.Use specific examples.

30 minutes

70 minutes

Classroom

Classroom

Copy of timetable for each trainee.Copy of specimen certificate of basic training.

Copy of company safety guide for each trainee. Copy of operators Safety Code for each trainee.Manufacturer’s handbook for truck to be used in training.Film


Day 1: 2 continued

Emphasise that trucks are designed to be perfectly safe, provided that they are not incorrectly used. Point out that there are laid down rules covering operating practices and that this course will concentrate throughout on safe, correct methods.

Issue company Safety Guide and briefly discuss the major points.

Ensure that trainees appreciate the need for rules and that the rules published by the company are fully understood. Cover the following points in particular:

- operators are responsible for carrying out a pre- use check of their truck (detailed information and instruction will be provided later)

- trucks must never be overloaded

-trucks must always be driven and operated by using safe, correct methods (detailed instruction to be given later)

- trucks must always be handled responsibly and with safety as a first priority

- trucks, loads and facilities must never be abused or handled roughly

- keys must always be taken out of unattended trucks.


Day 1: 2continued

Show a suitable safety film, related to truck operations.

Select the film carefully. Introduce the film, by pointing out that it shows dramatically, what is likely to happen when trucks are not handled correctly and skilfully. Ensure that trainees know in advance why the film is being shown, what to look for and that a discussion will be

Day 1: 3 1020-1100 INTRODUCTION TO TRUCK, CONTROLS AND INSTRUMENTS

Objective: On completion of this session, trainees will be aware of the main uses of a lift truck, will be able to name the main component parts and explain, in broad terms, their functions

The lift truck - its functions

held immediately afterwards. After showing, encourage trainees, by questioning, to identify what they considered to be bad/unsafe practices. (Do not expect, at this stage, technical explanations).

Close the entire session by reiterating the need for safety and correct operating practices.

Reiterate that a truck is a mobile lifting machine, it is not to be used for towing, dragging or pushing other vehicles or loads (unless proper attachments are fitted and used). trucks are designed to handle unit loads safely and easily.


Truck

46


Day 1; 3continued

The counterbalance Describe the truck to be used for training - a

electric or LPG Counterbalanced lift truck. Explain very briefly that weight on the fork arms at one end is counterbalanced by heavy weights

Identification of parts.

built in to the other end. Point out that this truck will be used throughout the course and that the practical test will also be conducted on the same machine.

Walk round the truck and name the various component parts. Where necessary, and to maintain interest, include a brief description of their function, but remember that at this stage the objective is to give an overall description of the truck, without too much technical detail.

The following should be included:

fork arms, carriage plate, securing pins and stop bolt, load backrest, mast, chains, rollers, hoist cylinders, tilt mechanism, counterbalance weight, engine compartment, battery, filler caps, rear steering wheels, front load wheels, capacity plate, overhead guard, fuel installation- LPG or diesel.


Day 1: 3continued

Controls and instruments. Turn now to the various hand and foot operated controls, and instruments. Identify each in turn and explain their functions. The following should be included: seat adjustment, steering wheel and assistor, parking brake, foot brake, accelerator,

Day 1: 4 1100-1300 SIMPLE MANOEUVRES-STARTING, MOVING, STEERING AND STOPPING

Objective: On completion of this session, trainees will be able to drive the unladen truck, under control, in both directions and steer accurately round an object.

Mounting and dismounting

Seat adjustment

clutch/inching control, horn, engine stop button, key switch, fuel gauge, oil pressure gauge, gear lever, direction control lever, load indicator, hour meter.

Teach the correct method of mounting and dismounting the truck.

Teach how to adjust seat to suit individual requirements.Encourage trainees to adjust seat, if necessary, each time they get on the truck during the course.


Truck. Drums/pallets.

48


Day 1: 4continued

Moving off and stopping (unladen truck) Teach how to move off smoothly, in forwards direction and in a straight line. Teach how to stop smoothly. Emphasise the need to check behind and around the truck before moving off,

Steering (unladen truck)

to keep hold of the steering assistor, to look in direction of travel and to control speed. Also to (1) apply parking brake and (2) put controls in neutral when stopped. Emphasise that trainees should always keep their limbs within the confines of the truck when moving. Emphasise also that trainees may only place their heads outside the lines of the truck for alignment purposes after necessary precautions have been taken to ensure that it is safe to do so. Teach how to move in the reverse direction , again in a straight line. Teach how trainees should turn in the seat for comfort and safety/control. Teach emergency stopping. Point out the need to consider the overall height of the truck in relation to any overhead obstructions.

Teach how to steer the truck forwards and in reverse, initially in an area with plenty of space for manoeuvring. Draw attention to the exaggerated rear-end swing and emphasise the need always to pay attention to this. Teach how to pivot, forwards and in reverse, from both sides of the truck, when steering around a drum or pallet in an open area. Pivot on the easier side (i.e. side readily viewed by the operator) first.

49


Day 1: 5

Day 1 : 6

1345-1510

1520 - 1550

MANOEUVRING IN CONFINED AREAS

Objective: On completion of this session, trainees will be capable of controlling acceleration and completing more difficult manoeuvring exercises with skill and confidence.

More difficult manoeuvres(unladen truck)

HYDRAULIC SYSTEM AND USE OF CONTROLS

Objective: On completion at this session, trainees will have a basic understanding of the hydraulic system on a lift truck and will be able to adjust fork arms and mast correctly for travel and parked positions

Definition

Lift truck hydraulic system

Pass on to further manoeuvring exercises, requiring progressively more skill in steering accurately and controlling the truck.(NB. Fork arms set by Instructor)

Explain that “hydraulics” is the power of a liquid under pressure passed through pipes.

Explain, in simple terms, the operation of the hydraulic system as applied to the fork truck. Name the various parts of the system.

85 minutes

30 mins

Area

Area

Truck. Items for constructing a simple course.

Flip chart/Wipe Board. Truck.

50


Day 1 : 6Continued

Day 1 : 7 1550-1630

Hygiene and oil levels

Hydraulic controls

Travel and parked positions(see Novice CourseDay 2 : 4, Page 29)

BATTERY CARE

Objective: On completion of this session, trainees will be aware of basic procedures for maintaining the efficiency of traction batteries.

Battery efficiency

NOTE:Refer to the Manufacturer’s recommendations

Explain the importance of cleanliness of the oil containers, and of maintaining oil levels in the reservoir at the manufacturer’s recommended level. Caution against overfilling when mast/forks elevated or when attachments have been fitted to the truck.Teach the operation of the hydraulic controls on the truck. Emphasise smooth and gentle operation. Mention that fork arms may be lowered under control with engine switched off.Explain how engine speed affects speed of lift.Teach the correct adjustment of mast and fork arms for travel and parked positions. Emphasise that, for safety reasons, hydraulic controls must only be operated:- By the operator when sitting in the driving seat- When the parking brake is fully applied

Prior to lesson commencing, trainees and instrucot must use the safety equipment and clothing specified.

Have the truck correctly parked, adjacent to the battery charger. Explain that the performance of the truck is largely determined by the effieciency of its traction battery. Point out the high cost of batteries and that the manufacturers guarantee will be afected if neglect can be proved.

40 mins Charger Area

Truck. Charging unit, truck logbook. Hydrometer. Container of de-mineralised water. Clean water and Eye ash bottle. Paper towels. Acid-proof apron. Safety goggles. Rubber gloves. Suitable waste container.

51


Day 1 : 7Continued

Day 1:7Cont’d

Safety rules

Disconnection of truck from battery.

Battery construction

Measuring and recording specific gravity

Emphasise the important safety rules:No smoking and no naked flames in the charging area. Explain the reasons for these strict rules.Explain also why metal objects should never be allowed to fall onto, or otherwise come into contact with, the top of the cells etc.Draw attention to the careful positioning of the truck in relation to the charge and the need to check that the parking brake is fully set.

Demonstrate how safely disconnect the truck from its traction battery and emphasise the importance of taking this action prior to any inspection or maintenance of the battery.

Explain how a battery is made up of a number of cells in which positive and negative plates are suspended in a solution of acid and de-mineralised water (called “electrolyte”). Emphasise the need for extreme care and that the clean water provided should be used immediately to wash off any acid solution which comes into contact with the skin. Point out, in particular, the location of eye-wash facilities.

Point out that the performance of a bettery is largely dependant on the way it is charged. Explain how an indication of the condition of a battery may be determined by the Specific Gravity (SG) of its electrolyte.

Show trainees the truck logbook and explain that SG readings should be entered before and after

52

Topping up

Charging Procedures

each charge.

Demonstrate the use of the hydrometer. Show how to take a reading and relate this information to the current state of the battery. Make sure that the electrolyte is returned to the cekk from which it was drawn.

Re emphasise that care should be taken during use of the hydrometer and that any accidental spillage of electrolyte should be wiped up and dried off immediatelyy.

Explain the need to keep cells topped up, but not overfilled. Show trainees how to determine when topping up is necessary.

Stress that only de-mineralised water must be used, using a clean glass or non-metallic container. Once more, remind trainees of the need to dry off any spillage without delay. Point out that vent plugs must be replaced and then tightened after topping up operations.

Stress the importance of ensuring that the electricity supply is turned off, before charging is attempted. Also that charger leads and plugs are examined for damage.

Demonstrate how to connect charger to battery, and how to prepare and switch on the charger.

53


Day 1:7Con’d

Switching off electricity Stress the need to switch off the mains electricity isolation switch and charger before attempting to disconnect the battery

Day 1:8 1630-1700

Disconnecting Leads

ROUTINE INSPECTION, TAKEOVER AND MAINTENANCE

Objective: On completion of this session, trainees will be capable of carrying out a through & systematic pre-use inspection (covering the aspects taught), & will know how to use the logbook correctly.

The importance of routine inspections.

Pre-use inspection.

IMPORTANT NOTE.The list of items to be checked is not finite.The manufacturers recommendations must take precedence.This is to ensure no specific item is left unchecked.

Demonstrate how to disconnect charger leads and how to hand them up safely.

Explain the purpose of carrying out a systematic inspection prior to use.

Teach the following;- Check condition of fork arms, carriage, stop bolts, load backrest, mast & rollers, chains, wheels, (nuts & rims) tyres (condition), cab/guard, & general bodywork.- Check seat for security & condition.- Check all motive & hydraulic controls for operation.- Check battery.- Check hydraulic fluid level (& for leaks).- Check brakes for effiency (whilst on move)- Check horn

30 Mins Area Truck, manufacturers handbook, logbook. De-mineralised water.

54


Day 1:8 - Check steering (whilst on the move)

Cont’d

Day 2:1 0830-0900

PLACE TRUCK BATTERY ON CHARGE

TAKING TRUCK BATTERY OFF CHARGE

Objective: On completeion of this training session, trainees will have participated, practically or by close observation, in the daily proceedures of taking a battery off charge. Under your supervsion, have a trainee take the truck off charge and another trainee take and record an SG reading.

CARRY OUT A ROUTINE TAKEOVER AND MAINTENANCE

- Check all gauges & warning lights.Explain the system of recording findings in the logbook provided.Explain laid down procedures when the truck is not fit for immediate use & emphasise that no attempt should be made to operate a faulty truck.

Under your supervsion, have one trainee park truck near to charger, have a second trainee take an SG reading and enter it into the logbook and the the remaining trainee put the truck on charge.

Prior to lession commencing trainee & instrucot must use the safety clothing and equipment specified.

Nominate one trainee to carry out a full routine inspection/check and complete log book / report.

30 mins Charger Area

See Battery Care, Aids and Equipment, page 51

As Above

55


Day 2 : 2 0900-0940 LIFT TRUCK STABILITY

Objective: On completion of this session, trainees will have a clear understanding of the factors which may affect the stability of the truck.

Engineering Principals.

Safe working load

See-saw principal

Stability

Load Centre

Explain carefully, but in clear and simple terms, the basic egineering principles of a counterbalanced lift truck.

Cover the following points:

- Maximum working loads (determined by the manufacturer) are indicated on the capacity plate on the truck.

- A truck & its load follow the same principles as a see-saw, with the front wheels as the Fulcrum & truck’s counterbalance weight opposing the weight of the load on the fork arms.

- Factors affecting stability (changes of speed & direction, weight, load centre & site conditions)

- Load centre is the distance from the centre of gravity of the load to the heel of the forks (calculated with the mast vertical). The manufacturer’s plate will state the capacities of the truck at specified load centre. If the load centre is lengthened, the load-carrying capacity will be reduced. But it does not follow that a shortening of the rated load centre permits an increase in load weight.

40 mins Classroom or office

Flip chart, Wipe board. Models to illustrate the see-saw principal


Day 2:2Cont’d

Perfect Balance

Lateral Instability

Longitudinal Stability

Truck Tipover

- Perfect balance is a dangerous state & in order to maintain positive stability, the working load indicated on the capacity plate has been arrived at by the manufacturer with due regard to all safety legislation & safe operating practices.

- Lateral instability may be caused by: turning at too high a speed for conditions, driving too close to a trench, turning with raised mast and/or load, turning across an incline, driving one wheel over holes/drainage, etc.

- Longitudinal instability may be caused by overloading the truck, by harsh/violent braking, by violent acceleration, by harsh or indiscriminate use of tilt with a load, by not inserting the fork arms, by operating incorrectly on a ramp or incline etc.

- Point out that, should a truck tip over ( Laterally or Longitudinally), serious or fatal injury can occur if the operator is trapped between the truck & the ground. Emphasise that, should a truck begin to tip over, the operator should:- Stay within the truck,- Hold on firmly,- Brace feet.- Lean away from point of impact.

57


Day 2 : 3 0940-1010&1020 1230

LOAD HANDLING

- BUILDING FREE-STANDING STACKS

Objective: On completion of this session, trainees will be skilled at stacking/destacking both flat & corner-post pallets at various heights.

Adjusting spread of fork arms

Picking up/setting down flat pallets.

Stacking/destacking loaded flat pallets, (straight line approach).

Teach the method of adjusting the spread of fork arms and explain the reasons for making adjustments.

Teach how to pick up and set down correctly an unladen pallet, making a straight-ahead approach. Point out in particular:- Lining up fork arms centrally & squarely with pallet at the earliest opportunity.- Allowing correct distance between fork arm tips & pallet before levelling fork arms for insertion.- How to judge from driving position when the mast is at vertical.

Teach how to stack/destack laden pallets, making a straight line approach, & at various levels. Explain the importance of sitting a stack against a stack within a warehouse( where applicable).

- Check that the floor is in a sound & level condition.- Never stack against a wall or doorway.- Never obscure fire extinguishers, Alarm points or emergency exits.

160 mins Area Various Loads/Pallets.

58


Day 2:3 Cont’d

Stacking/destacking loaded flat pallets (90º approach)

Stacking loads in front of vertical face.

Corner post pallets.

Picking up/setting down corner post pallets.

Stacking / destacking post pallets.Undercutting pallets/loads-all types. (See novice Course Day 4:2, page 35).

Explain the factors to be considered when stacking:- Ensure goods on each pallet are secure & levelled off.- Remember the pallet & bottom layer of the bottom load must support the weight of the entire stack.- Stack close together but allow for forks to protrude if necessary beyond the back of the pallet.

Teach the skills of stacking/destacking, making a 90º approach from both sides but in an open area, & at various levels.

Repeat this exercise, but approaching in confined area/aisle.

Teach how to stack loaded pallets, squarely & within 150mm (6 inches) of vertical face.

Explain the uses of these types & explain the differences in handling methods.

Teach how to set down & pick up a post pallet close to vertical face (undercutting if necessary).

Teach how to stack/destack corner post pallets, at various levels & between adjoining stacks of other corner post pallets, making a straight-line approach.Repeat as above, but making a 90º approach from both sides.Point out that no attempt should be made to stack corner-post pallets on which the cupped feet are damaged.


Day 2:4

Day 2: 5

1230-1300&1345-1510

1520-1650

LOAD HANDLING - SCAFFOLDING/RACKING SYSTEMS

Objective: On completion of this session, trainees will be skilled in stacking/destacking loaded pallets at all levels of scaffolding/ racking system.

Scaffold/racking

VEHICLE LOADING & UNLOADING.

Objective: On completion of this session, trainees will be able to load & unload a flat-bed vehicle from both sides.

Safety checks.

Explain the purpose of Scaffold/Racking systems.

Explain the load limitations of Beam sections. Teach how to stack or destack within scaffolding or racking, at various levels, from a straight-line approach & from a 90º approach (both sides, & in Test conditions).

Explain the safety checks & precautions necessary prior to loading/unloading;

- Ensure that the vehicles driver is aware of your intentions.- Ensure that the lorry engine is stopped.- Ensure that the lorry/trailer has its brake set.- Ensure that the vehicle wheels are chocked.- Ensure, before loading, that the loading platform is clear of debris & strong enough to withstand the weight of the pallets or load.

115 mins

90 mins

Area

Area/Classroom

Truck. Scaffolding - Racking. Various loads

Truck. Flat-bed vehicle, Suitable pallet loads. Wheel chocks.

60

Day 2:5 Cont’d

Day 2:6

Day 3: 1

1650-1700

0830-0900

Sequence of loading & unloading

Stacking height.

Loading Unloading.

Place truck battery on charge

Taking truck off battery on charge Carry out routine takeover & maintenance.

- Avoid placing heavy pallet loads over unsupported parts of semi-trailers, without taking adequate precautions to prevent upending.- When unloading unsupported semi-trailers, take adequate precautions to prevent upending.

Explain that, wherever possible, vehicles should be loaded starting from the front, working from side to side & distributing the load evenly.Explain the significance of plated & axle weights.Unloading should be in reverse of this process.

Explain the maximum stacking heights with company stock or safe height if using corner post pallets.Teach how to load, by gating against the headboard & adjacent load, & from both sides.Teach how to unload.

Under your supervsion, have one trainee park trucj near o charger, have a second trainee take an SG reading and top up battery as required. Enter it in the log book and have the remaining trainne put the truck on charge.

Use instructors notes shown on Day 2:1, page 55.30 Mins Charger

Area

See battery Care (objectives/content

column) day 1:7 Page 51)

Use Aids & Equipment shown on Day 1:7,

Page 51

61


Day 3: 2

Day 3: 3

Day 3: 4

0900-1010&1020-1110

1020-1100

1100-1300

HANDLING LOADS-CONFINED AREAS & RAMPS.Objective: On completion of this constructing session, trainees will have reached courses. Test standard in the critical skills, & will also be able to negotiate ramps safely with an laden & unladen truck.

Stacking/Destacking various pallets

Driving on ramp or gradient (unladen truck)

WRITTEN TEST

PRACTICAL TEST - pre-use inspectionPRACTICAL TEST

Practical Test/s Basic operating skills

Further practice in stacking/destacking various pallets, including block building.

- The need to adjust height of fork arms before & after but not whilst driving on the ramp.- The need to control speed.- The method of controlling speed.- The line to take whilst on the ramp (emphasise the dangers of turning across a gradient).Explain action if obliged to park on a ramp or gradient.

Trainees together, with Instructor invigorating.

Individual testing of trainees (others out of sight & hearing).Carry out test precisely as prescribed.Each trainee in turn.Only trainee under test & Instructor/examiner to be present.

120 mins Area Truck. Various loads. dump or Incline. Items for constructing courses.

Test papers.

Truck. Marking sheet/clipboard.

Truck. Test course as laid down. Marking sheet as laid down.

Day 3: 5 COURSE CLOSUREReiterate the importance of continuing to operate safely & correctly.Issue course results if appropriate.Bring to each trainees attention the “important note for lift truck instructors” on the introduction page.

Classroom or Office

Certificate of Basic training if prepared.

62TIMETABLE

2.5 Day (20 hr) Basic Training Course for Existing but Untrained operators.(3 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric Counterbalanced Lift Truck, Rider-operated

Day Classroom Area Area Area Area0830 0900 0900 1010 1020 1100 1100 1300 1345 1510 1520

15501550 1630

1620 1700

1Admin.


Code & FilmIntro. to Truck,correct driving

Basic manoeuvres Manoeuvring in confined areas Hydraulic system &

use of controls

Battery Care

Routine inspection,

Take-over & Maintenance

Area Classroom Area Area Area Area Area0830 0900 0900 0940 0940 1010 1020 1230 1230 1300 1345 1510 1520 1650 1650 1700

2Battery charge

& Routine inspection, take-over &

mntce


Load handling,

building free standing

stack

Load Handling

Building free standing stacks

Load handling

racking or scaffolding

Load handling

Racking/scaffold systems

Vehicle loading and unloading

Battery Charging

Area Area Area Classroom Area Classroom0830 0900 0900 1010 1020 1110 1110 1150 1150 1350 1350 1400

3Battery

charge & Routine

inspection, take-over & mntce

Load handling - Variety of loads in confined areas

including ramp/gradients

Load handling - Variety of loads in confined areas inc.,

ramp/gradients

Written testTests

Practical inspection &

Basic operating skills

Course closure

63

MINIMUM DURATION OF BASIC TRAINING

Basic training for operators of Counterbalanced industrial lift trucks.The course duration is unlikely to be shorter than the following norms;

Ratio: Trainee: Instructor: Truck

For Novice Operators: 3:1:1 2:1:1 1:1:1

Overall Duration * 37.5 hrs 30 hrs 22 hrs

Including practical content (demonstration, explanation and supervised practice) of not less than. 31.5 hrs 24.5 hrs 17 hrs

For Existing operators:

Overall Duration *

including practical content of not less than

20 hrs

15 hrs

16.5 hrs

12 hrs

13 hrs

9 hrs

* Covering practical & theory instruction, practice (at the wheel) by each trainee, Practical test, written test, practical inspection test & course administration.

64

ADJUSTING PROGRAMMES

(Basic Training) ACCORDINGTO NUMBER OF TRAINEESThe detailed information provided in the preceding pages is based on the maximum acceptable ratio of:3 trainees to 1 truck.

The following timetables are included for guidance where other ratios are applicable. These may be usedin conjunction with the earlier material to adapt course documentation for any of the acceptable ratios,provided that appropriate adjustments to timings etc. are made.

65

TIMETABLE

4 Day (30 hr) Basic Training Course for Novice lift truck operators(2 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric counterbalanced lift truck, Rider-operated


1Admin.





Starting, Moving, Steering & Stopping Basic Manoeuvring Exercises

Area Area Classroom Area Area Area0830 1010 1020 1110 1110 1200 1200 1250 1330 1510 1520 1610 1610 1700

2General practice

manoeuvring in confined areasLift truck stability

Hydraulic system & use

of controls

Further driving incl.,

hydraulic controls

Further practiceusing hydraulic controls

Load weight assessment

Pre-use Inspection, take-

over & maintenance of

Lift TruckArea Area Area Area

0830 1010 1020 1110 1110 1250 1330 1420 1420 1510 1520 1700


practiceLoad Weight Handling Load handling -

operating practice Further load

handlingVehicle loading &

unloadingVehicle loading & unloading

Area Area Area Classroom Area Area0830 1010 1020 1250 1330 1420 1420 1500 1500 120 1520 1700


operating practice in confined areas

Load handling - further operating practice in confined areas

Further practice

Written Test

Test - practical

Inspection

Practical test/s of basic

operating skills

Course closure


TIMETABLE

3 Day (22 hr) Basic Training Course for Novice lift truck operators(1 trainees: 1 Instructor: 1 truck) Diesel / LPG /Electric counterbalanced Lift Truck, Rider-operated


1Admin.





Basic Manoeuvring ExercisesFurther driving practice

Area Area Classroom Area Area Area0830 1010 1020 1110 1110 1200 1200 1250 1330 1420 1420 1510 1520 1610 1610 1700

2Further driving practice Lift truck

stabilityHydraulic

system & use of controls

Further driving incl.,

hydraulic controls

Load weight assessment

Load Handling Load HandlingPre-use Inspection,

take-over & maintenance of Lift

Truck

Area Area Area Classroom Area Area0830 1010 1020 1200 1200 1250 1330 1510 1525 1605 1605 1620 1620 1655


practiceVehicle loading &

unloadingLoad handling

racking or scaffolding

Load handling racking or scaffoldingWritten

Test

Test - practical

Inspection

Practical test/s of

basic Operating skills

close


Alternative TIMETABLE

3 Day (20 hr) Basic Training Course for Existing lift truck operators(3 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric counterbalanced Lift Truck, Rider-operated

Day Classroom Area Area Area0830 0900 0900 1010 1020 1250 1330 1510 1520 1630 1630 1700

1Admin.



Controls & InstrumentsStarting, Moving, Steering & Stopping

Basic Manoeuvring Exercises Manoeuvring in confined areas

Area Classroom Area Area Area0830 0900 0930 1010 1020 1250 1330 1510 1520 1650 1650 1700

2Hydraulic system &

use of controlsLift truck stability Load handling - Building free-standing

stacksLoad handling into & out of

Racking/scaffoldingVehicle

loading & unloading

Pre-use Inspection, take-

over & maintenance of

Lift TruckArea Area Classroom Area Area Classroom

0830 1010 1020 1135 1135 1215 1215 1250 1330 1510 1520 1545

3* R.I Handling variety of loads in

confined areas, inc. Ramp/Gradient work

Load handling - operating practice

Written Test Test - practical

Inspection

Practical test/s of basic operating skills

Course closure


TIMETABLE

2.5 Day (16.5 hr) Basic Training Course for Existing, but Untrained lift truck operators(2 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric Counterbalanced Lift Truck, Rider-operated

Day Classroom Area Area Area Area0830 0900 0900 1010 1025 1130 1130 1230 1330 1510 1515 1545 1545 1630 1630 1700

1Admin.



followed by correct driving

Basic Manoeuvring Manoeuvring in confined areas

Hydraulic system &

use of controls

Practice liftusing hydraulics

Inspection take-over & mntce

Area Area Area Area0830 0900 0900 0920 0920 1010 1025 1115 1115 1230 1330 1500 1515 1700

2Inspection

take-over & mntce


Building free-

standing stacks

Building stacks Load handling into & out of

Racking/scaffolding

Vehicle loading & unloading

Handling variety of loads in confined areas, inc. Ramp/Gradient work

Area Area Area Classroom0830 0900 0900 0930 0930 1010 1025 1100 1100 1200 1200

3* R.I Load

handling - operating practice

Written Test Test Practical

inspection

Practical test/s of

basic operating

skills

Close

* R.I Wherever stated means Routine Inspections, Take-over & Maintenance of the Lift Truck

69

TIMETABLE

2 Day (13 hr) Basic Training Course for Existing, but Untrained lift truck operators(1 trainees: 1 Instructor: 1 truck) Diesel / LPG / Electric counterbalanced Lift Truck, Rider-operated

Day Classroom Area Area Area0830 0900 0900 1010 1025 1100 1100 1030 1130 1230 1330 1400 1400 1425 1425 1445 1515 1545 1545

16301630 1700

1Admin.


Code & FilmIntro. to Truck, correct driving

Basic Manoeuvring

Manoeuvring in confined

areas

Hydraulic system &

use of controls

Inspection take-over & mntce


Building free-

standing stacks

Area Area Area Classroom Area Area0830 0900 0900 1010 1025 1130 1130 1230 1330 1350 1350 1430 1430 1445 1500 1600 1600

2Inspection

take-over & mntce

Load handling into & out of Racking/scaffolding

Vehicle loading & unloading

Handling variety of loads in confined

areas, inc. Ramp/Gradient work

Load handling - operating practice

Written Test

Test Practical

inspection

Practical test/s of basic

operating skills

Close

70

Documents

Fork Lift Instructor