Forklift & Telehandler Operator Training

1. Introduction to Forklifts and Telehandlers

Participants are introduced to the different types of forklifts and telehandlers used in industrial environments, including their functions, limitations and typical applications.

Training covers:

• Counterbalance forklifts.
• Rough terrain forklifts.
• Reach trucks.
• Telescopic handlers.
• Fork attachments.
• Material handling attachments.
• Load handling applications.
• Differences between forklifts and telehandlers.
• Typical workplace hazards.

Forklifts are commonly used for lifting and transporting palletized loads, while telehandlers are used where extended reach, height or rough-terrain capability is required.

2. Legal Requirements, Standards and Site Rules

This module explains the legal and procedural requirements related to forklift and telehandler operation.

Participants learn that operators must be trained, authorized and competent before using the equipment. OSHA states that only trained and competent operators are permitted to operate powered industrial trucks, and that operator training and evaluation are required.

Training covers:

• Operator authorization.
• Employer and supervisor responsibilities.
• Site-specific operating procedures.
• Workplace transport rules.
• Speed limits and traffic routes.
• Safe use of attachments.
• Reporting unsafe equipment.
• Defect reporting procedures.
• Stop-work authority.

3. Pre-Use Inspection and Safety Checks

Before operating a forklift or telehandler, the operator must inspect the machine to confirm that it is safe for use.

Inspection points include:

• Tyres and wheels.
• Forks and fork carriage.
• Mast, boom or lifting mechanism.
• Hydraulic hoses and cylinders.
• Fluid leaks.
• Brakes and steering.
• Lights, horn and warning alarms.
• Seat belt.
• Mirrors and cameras.
• Load backrest.
• Attachment locking system.
• Operator cab condition.
• Fire extinguisher, where fitted.
• Warning lights and dashboard indicators.

The operator must not use equipment with serious defects. Unsafe machines should be isolated, reported and repaired before being returned to service.

4. Understanding Load Capacity and Load Charts

Forklift and telehandler operators must understand that every machine has a rated capacity, and that capacity changes depending on load position, lifting height, boom extension, attachment type and operating conditions.

This is especially important for telehandlers because their capacity can reduce significantly as the boom extends or raises. HSE guidance for telehandlers highlights stability and safe traffic routes as key safety issues, and telehandler safety guidance notes that ground conditions affect the stability of the machine and load.

Training covers:

• Safe Working Load.
• Working Load Limit.
• Load centre.
• Load charts.
• Rated capacity.
• Boom extension effect.
• Fork position.
• Attachment effect on capacity.
• Dynamic loading.
• Load stability.
• Overload prevention.

Key info: operators must never guess lifting capacity. The load chart and manufacturer’s instructions must always be followed.

5. Load Weight and Centre of Gravity

Operators learn how to assess the weight and balance of a load before lifting.

A load may become unstable if its centre of gravity is not central, if the load is not secured, or if the load is lifted too high during travel.

Training covers:

• Establishing load weight.
• Reading load labels and delivery documents.
• Understanding load centre.
• Identifying offset loads.
• Handling irregular loads.
• Checking load stability.
• Avoiding unstable or damaged pallets.
• Securing loose materials.
• Recognizing when lifting is unsafe.

This module helps prevent dropped loads, machine instability and overturning.

6. Safe Lifting and Load Handling

Participants are trained in safe lifting, carrying, placing and stacking techniques.

Training covers:

• Correct approach to the load.
• Fork spacing and positioning.
• Inserting forks fully under the load.
• Tilting the mast correctly.
• Keeping the load stable.
• Travelling with the load low.
• Avoiding sudden braking or sharp turning.
• Positioning loads accurately.
• Stacking and de-stacking.
• Loading and unloading trucks.
• Working near racks, containers and structures.
• Avoiding people under raised loads.

For telehandlers, additional attention is given to boom extension, boom height, stabilizers, outriggers and safe positioning before lifting.

7. Travelling Safely With Loads

Moving with a load is one of the most common risk areas for forklift and telehandler operations. Operators must maintain visibility, control speed and keep the machine stable.

Training covers:

• Travelling with forks or load low.
• Maintaining clear visibility.
• Travelling in reverse when the load blocks forward view.
• Using mirrors and cameras.
• Sounding the horn at blind corners.
• Keeping safe distance from pedestrians.
• Avoiding sudden movements.
• Driving on ramps and slopes.
• Avoiding travel with raised loads.
• Reducing speed in congested areas.

HSE advises that when a load blocks forward vision, it may be safer to travel in reverse, and operators should take extra care where people cannot be fully excluded from the work area.

8. Stability and Overturn Prevention

Forklifts and telehandlers can overturn if operated incorrectly. This module teaches participants how to maintain stability and avoid rollover incidents.

Training covers:

• Stability triangle.
• Centre of gravity.
• Load height and machine balance.
• Turning with loads.
• Operating on slopes.
• Ground condition assessment.
• Effect of speed on stability.
• Boom extension and telehandler stability.
• Side loading risks.
• Suspended load hazards.
• Seat belt use.
• ROPS and FOPS awareness.

Key info: the higher and further forward the load is, the greater the instability risk, especially when turning, braking or operating on uneven ground.

9. Workplace Traffic Management

Forklift and telehandler safety depends not only on the operator, but also on the work environment.

Training covers:

• Vehicle and pedestrian segregation.
• Traffic routes.
• One-way systems.
• Speed control.
• Blind corners.
• Loading zones.
• Reversing areas.
• Signage and warning lights.
• Exclusion zones.
• Banksman and spotter use.
• Parking areas.
• Working near other mobile equipment.

HSE workplace transport guidance emphasizes controlling risks where vehicles are used at work, including safe routes and separation of people from moving vehicles.

10. Working With Attachments

Forklifts and telehandlers may use different attachments depending on the task. Operators must understand that attachments can change the equipment’s capacity, stability and handling behaviour.

Training covers:

• Forks.
• Buckets.
• Jibs.
• Lifting hooks.
• Man baskets, where legally permitted and approved.
• Fork extensions.
• Clamps.
• Material handling arms.
• Quick couplers.
• Attachment inspection.
• Attachment locking verification.
• Manufacturer approval.
• Load chart changes caused by attachments.

Only suitable and approved attachments should be used, and operators must never improvise lifting arrangements.

11. Working Around Proximity Hazards

Operators must be able to identify hazards around the work area before and during operation.

Proximity hazards include:

• Pedestrians.
• Other vehicles.
• Overhead power lines.
• Structures and pipe racks.
• Scaffolding.
• Excavations and trenches.
• Quay edges.
• Loading bays.
• Doorways and low-clearance areas.
• Slopes and ramps.
• Uneven or soft ground.
• Poor lighting.
• Dust, rain or reduced visibility.
• Hazardous materials.
• Congested work areas.

The operator must stop the activity when the environment becomes unsafe.

12. Communication and Banksman Support

Clear communication is essential when visibility is restricted or when operating in busy industrial areas.

Training covers:

• Hand signals.
• Radio communication.
• Working with a banksman.
• Stop signal.
• Emergency communication.
• Reversing communication.
• Loading and unloading communication.
• Communication failure procedures.
• One signal person rule.

The operator must not continue moving if signals are unclear or if the banksman is not visible.

13. Loading and Unloading Trucks

Loading and unloading trucks is one of the most common activities performed by forklift and telehandler operators.

Training covers:

• Checking truck stability.
• Verifying trailer condition.
• Using wheel chocks where required.
• Checking dock plates and ramps.
• Load placement.
• Load distribution.
• Avoiding trailer movement.
• Working near drivers and pedestrians.
• Preventing collision with truck sides.
• Safe reversing from trailers.
• Communication with truck drivers.

This module helps prevent falls from loading docks, trailer instability, dropped loads and collisions.

14. Parking, Shutdown and Securing the Equipment

At the end of operation, the machine must be parked and secured correctly.

Training covers:

• Parking on level ground.
• Lowering forks, boom or attachment.
• Neutralizing controls.
• Applying parking brake.
• Switching off the engine.
• Removing the key.
• Securing the machine.
• Refuelling or battery charging precautions.
• Reporting defects.
• Post-use inspection.

Correct shutdown prevents unintended movement, unauthorized use and equipment damage.