Fundamental Operational Instructions for Fork Truck

TM 38-400/NAVSUP PUB 572/AFMAN 23-210 MCO 4450.14/DLAM 4145.12

methods of palletizing and stacking, fire aisles, alarm

program,

which

boxes, and sprinkler systems.

includes regular and periodic servicing (or battery

charging), washing, lubrication, cleaning, the checking

(8) Explanation of the appropriate OSHA

of tire condition and hydraulic system (if any), and

requirements applicable to safe operations.

painting.

(4) An explanation of the results of misusing

4-36.

Fundamental Operational Instructions for

fork trucks. This could include an exhibition of worn and

Fork Truck.

broken parts to illustrate the additional cost incurred as a

a. Preparation. One fork truck should be provided

result of improper operation of the equipment. The

for every two students. All fork trucks will be equipped

instructor should point out the equipment. The instructor

with over-head guards. The area selected for training

should also point out the additional dangers involved in

should be level, with paved surface, and should be free

operating equipment which has been damaged by

of other traffic.

misuse.

b. Review of previous instructions. Instructions

(5) Review of savings effected by the use of

should include a review of previous classroom

mechanical equipment. The review should emphasize

discussions on the various controls, preventive

the saving of time in delivering needed supplies, earlier

maintenance,

warehousing

procedures,

stacking

release of railroad equipment, saving of space by

methods, and safety rules pertaining to the operation of

increased stacking height, and more compact storing of

fork trucks.

material.

c. Operational condition of vehicle.

(6) Discussion of safe loading practices, as

(1) Before taking their place on the truck, the

outlined below:

trainees will be instructed to check the following:

(a) Safe load.

Overloading of fork

(a) Gasoline.

trucks is strictly prohibited. The truck will safely lift and

(b) Water.

carry no more than its rated capacity. Among the

dangers of overloading are the possibility of injury to the

(d) Tires.

operator, damage to the cargo, damage to the pump

and lift mechanism, and excessive wear on the tires,

(e) Fire extinguisher (when truck is so

engine, or electric motor.

equipped).

(b) Determination of safe loading. A

(f) Security of forks.

fork truck will tip forward if the load on the forks exceeds

(2) After mounting the truck, the trainee will

the lift capacity of the truck. The manufacturer has

check the following:

established the truckload rating (expressed in pounds of

(a) Horn.

load on the fork) and the allowable distance in inches

(b) Parking brake and foot brake.

from the heel of the forks to the center of gravity of the

load. This distance is known as the load center.

neutral).

d. Instructor's demonstration.

The instructor

Some manufacturers specify a number of pounds

should demonstrate to the entire class how to operate

capacity with a particular length of load. Others specify

the machine forward and backward. At this point, the

a number of pounds capacity at a given number of

trainees should be cautioned against traveling with the

inches from the heel of the fork. Some give an inch-

foot resting on the clutch pedal ("riding the clutch") as

pound rating based on the distance of the load center

this results in the loss of tension in the clutch springs,

from the heel of the fork, while others base their inch-

allowing the clutch to slip and causing excessive wear.

pound rating on the distance from the center of the load

The instructor should take particular care to explain that

to the center of the front axle.

forks should always be raised just high enough for safe

(d) Uniformly distributed load. When a

clearance, yet low enough to permit a clear view ahead

load is uniformly distributed throughout the length (i.e.,

when traveling either with or without a load. If the load's

parallel to the prongs of the fork), the center of gravity

size obstructs the operator's forward view; drive the fork

will be located at half such length. When a load is not

truck in reverse.

uniformly distributed throughout the length, care must

e. Trainee's practice.

be taken to determine the distance from the heel of the

(1) Basic operation. The trainee should now

forks to the accurate center of gravity.

drive the machine in a straight line forward and

(7) The instructor's explanation of the details

of warehousing procedures should include a discussion

of warehouse aisle widths, selecting and storing stock,

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