Craftsman Forklift Operator cheat sheet

OSHA general industry standard 29 CFR 1910.178 governs powered industrial trucks; training must be formal, practical, and evaluated, with refresher evaluation at least every 3 years.

Operator authorization is site-specific and truck-type-specific: an operator trained on a counterbalanced sit-down rider is not automatically authorized for a reach truck or order picker.

Pre-shift inspection is a regulatory duty, not a courtesy; a truck found defective must be tagged out of service and reported before it is used again.

Three prohibited practices under 1910.178: riders on forks or pallets, lifting people with the forks unless a securely attached approved platform is used, and leaving a running truck unattended.

A truck is 'unattended' when the operator is more than 25 feet away or the truck is out of sight; then forks are fully lowered, controls neutralized, power off, and brake set.

Refresher training and evaluation are triggered by an accident or near-miss, unsafe operation observed, a workplace change, or a different truck type - not only by the 3-year clock.

Employer duties include hazard assessment, traffic routing, pedestrian separation, and enforcing seat belt and restraint use; operator duties include reporting damage and refusing unsafe tasks.

Recordkeeping: training certification must show operator name, training date, evaluation date, and the identity of the trainer or evaluator.

Classes: I electric rider, II electric narrow aisle, III electric hand/rider pallet, IV IC cushion tire, V IC pneumatic tire, VI electric/IC tow tractor, VII rough terrain.

Capacity plate states rated load at a given load center (typically 24 in) and lift height; capacity decreases as load center moves forward or height increases.

Data plate items to verify: model, serial, mast type, attachment, rated capacity, load center, and battery or fuel type; a missing or unreadable plate makes the truck unusable.

Pre-operation check sequence: engine off visual walk-around, fluid levels and leaks, forks and heels, chains and tension, mast and hoses, tires and wheels, overhead guard, data plate, seat belt, then operational checks.

Operational checks: horn, lights, backup alarm, service brake, parking brake, steering, tilt and lift functions, and deadman or seat switch.

Electric trucks: check battery connector, cable chafing, electrolyte level if applicable, hour meter, and that the charger is disconnected before moving.

LPG trucks: check tank mounting and locating pin, hose condition, and that the tank is not leaking; gasoline and diesel: fuel level, no leaks, air filter condition.

Forks: inspect heels for wear (reject beyond about 10 percent heel thickness loss), cracks, bent shanks, and missing or worn stop or locking pins.

Stability triangle: the center of gravity of the truck plus load must stay inside the triangle formed by the two front wheels and the steer axle pivot.

Longitudinal stability is lost by overloading, forward load center, or tilting forward with a raised load; lateral stability is lost by turning too fast, especially with a raised load.

Capacity rule: rated capacity applies at the stated load center; each additional inch of load center reduces capacity, so use the capacity chart for the actual load center and height.

Load center is the horizontal distance from the vertical face of the forks to the load's center of gravity; attachments such as clamps and extenders shift it forward and require derating.

Moment formula: load weight × load center distance must not exceed the truck's rated moment; adding an attachment reduces net capacity by its own weight and its own load center.

Safe load handling: approach square, spread forks as wide as the load allows, insert fully so the load rests against the carriage, lift clear, tilt back slightly, then travel.

Never travel with the load raised: keep forks 4 to 6 inches above the floor (about 10 to 15 cm) and the mast tilted back.

Stacking rules: check overhead clearance, ensure the stack is stable and square, do not exceed the rack or floor rating, and never let anyone stand under a raised load.

Mount and dismount facing the truck using three points of contact; never grab the steering wheel as a handhold.

Seat belt must be worn on sit-down trucks with overhead guards; the restraint keeps the operator inside the compartment in a tip-over.

Travel with forks trailing on a counterbalanced truck, load low and tilted back; travel in reverse when the load blocks forward visibility, except when climbing a ramp.

Ramps and grades: travel with the load uphill whether forward or reverse - loaded, forks point uphill; unloaded, forks point downhill. Never turn on a ramp or grade.

Speed rule: no faster than a brisk walk, slower in congested areas, at intersections, and when the load is high or wide; sound the horn at blind corners.

Dock and trailer work: verify trailer wheels are chocked or the vehicle is restrained, check the floor condition and dock plate rating, and use dock lights in dark trailers.

Parking: fully lower forks flat, neutralize controls, set parking brake, turn off power, remove the key; on grades, chock the wheels.

Rail crossings, wet floors, and floor joints: cross slowly and at an angle where possible, and never drive over objects or debris that could destabilize the load.

Pedestrians have the right of way; the operator must stop and make eye contact or receive an acknowledged signal before proceeding.

Blind corner rule: slow, sound the horn, and stop where visibility is blocked; mirrors at blind corners supplement but do not replace the stop.

Keep a safe following distance - about three truck lengths - and never allow a pedestrian to walk between a truck and a fixed structure or rack.

Pedestrian exclusion zones: mark walkways with barriers or rails, keep aisle intersections clear, and prohibit pedestrians in the truck operating area during busy periods.

Site traffic controls: one-way aisles where possible, speed limits posted, stop signs at intersections, designated charging and parking areas, and separation of truck and foot traffic.

Visibility aids: high-visibility vests for pedestrians, lights and strobes on trucks, horns and backup alarms tested daily, and mirrors or convex mirrors at blind spots.

Never allow anyone under raised forks, on the forks, or on the counterweight; use an approved platform or a personnel lift for overhead work.

Load and rack awareness: check rack capacity labels, avoid striking rack uprights, and report damaged racking immediately since impact damage can cause collapse.

Common incident causes: speed, poor visibility, unbalanced or overloaded loads, tip-over during turns, pedestrian strikes, and dock or trailer edge failures.

Tip-over response: stay in the seat, brace feet, hold the wheel, and lean away from the direction of the fall; do not jump, because the overhead guard can crush a jumping operator.

If the truck begins to tip, do not attempt to jump clear or extend limbs outside the compartment; the restraint and guard are designed to protect a seated operator.

Incident response sequence: stop and secure the truck, render aid and call for emergency help, isolate the area, preserve the scene, then report to the supervisor and complete documentation.

Report all incidents including near-misses and property or rack damage; near-miss data is the primary tool for preventing the next injury.

Hazard identification: scan for pedestrians, blind corners, wet or oily floors, loose loads, overhead obstructions, low clearance, and damaged racking before and during travel.

Fuel and battery hazards: no smoking or open flame near LPG or refueling areas, ventilate battery charging areas for hydrogen, and use PPE for electrolyte handling.

Accident prevention: pre-shift inspections, load checks, speed discipline, horn use at blind spots, and stopping when visibility or control is compromised.

Only trained and authorized personnel perform refueling or battery changes; the operator secures the truck, turns off power, and sets the brake before servicing.

LPG: change cylinders outdoors or in a well-ventilated area, close the valve, check the O-ring and hose, mount with the locating pin engaged, and check for leaks by smell or soap solution, never flame.

Battery charging: open the compartment or ventilate the area, keep sparks and flames away, wear face and hand protection, and add water after charging, not before.

Battery changing: use the correct lifting equipment, keep the battery level, and never stand under a suspended battery; follow the site's changing procedure.

Refueling: engine off, no smoking, bond and ground containers where required, clean up spills with the site's spill kit, and report any fuel leak.

Daily care: clean the truck, remove debris from the mast and wheels, check fluid levels, and report leaks, damaged hoses, or worn tires immediately.

Defect tagging: any defect affecting safe operation - brakes, steering, horn, lights, chains, forks, or leaks - requires lockout/tagout and removal from service until repaired.

Maintenance records: log inspections, repairs, and battery or fuel servicing; never modify the truck or add an attachment without manufacturer approval and a revised capacity plate.

Evaluation components: pre-use inspection demonstration, control familiarization, load handling, travel and maneuvering, stacking and de-stacking, parking, and pedestrian awareness.

Scoring is pass/fail against observable criteria: forks positioned squarely, load stable, no contact with racking, horn at blind corners, seat belt worn, and smooth control use.

Load handling test: pick a load from a rack or floor, transport it through a course, and set it down squarely without dragging, dropping, or striking the rack.

Maneuvering test: forward and reverse through a marked aisle, right-angle turns, and a ramp or simulated grade with the load oriented correctly.

Stacking test: place and retrieve a load at height, checking overhead clearance and rack capacity, with the load level and fully seated on the rack beams.

Parking test: forks flat on the floor, controls neutral, brake set, power off, key removed, and the truck left in a designated area.

Pedestrian scenario: stop for a pedestrian in the aisle, make eye contact, and proceed only when the path is clear and acknowledged.

Common failure points: traveling with the load raised, turning on a grade, missing the horn at a blind corner, no seat belt, and failing to inspect before operating.