A forklift is a useful machine... if you follow the rules!

Loaders, like excavators and dump trucks, are among the most popular among special equipment. The machines can be used on a construction site, in a production workshop, warehouse, or logistics center. Today, having a permit to drive a forklift, you can find a sought-after, high-paying job. Modern models are equipped with convenient levers and pedals, which greatly simplifies the control of front-end loaders and forklifts, both with manual (manual) and automatic (automatic) transmissions.

Types of forklift control levers

The mechanisms responsible for the movement, control and stopping of equipment are conventionally divided into the following groups:

Travel levers

A loader with a manual transmission and an automatic transmission with mechanical gear selection is equipped with two shift knobs - one for selecting the direction of travel, the second for selecting a gear. Using these controls, you can move forward/backward and change speed - two to four gears for moving forward and one to two for moving backward.

If you set the driving direction switch lever to the “R” position, the equipment will begin to move backwards, a special signal will sound, the headlights will light up, or the reverse signal will turn on.

To start moving and change the direction of movement of a self-propelled material handling machine, the brake pedal must be pressed before switching the lever. To switch the direction back and forth and vice versa, the machine must be completely stopped.

Gear shift lever

Before starting to operate the gear shift lever (for a fully automatic transmission), the brake pedal is depressed. After the pressure on the brake pedal is released, the car begins to move slowly. In this case, the speed shift knob is in any position except neutral. The brake pedal is fully released only after you are completely ready to move.

The equipment is equipped with one shift lever located on the steering column. There are two to four gears for forward movement and one to two for reverse movement. In the “R” position, the reverse lights come on or the horn sounds. Switching the direction of movement of the vehicle from front to rear and vice versa is carried out only after the vehicle has completely stopped.

Manual control of the loader

Manual control of a loader with an automatic transmission with a mechanical gear selection involves working with a direction shift lever corresponding to the steering wheel drive switch (for a fully automatic transmission). Before starting the equipment, the lever must be set to the neutral position. Otherwise, the special equipment will not start.

Steering column tilt lever

Before starting the loader engine, the operator must sit in the driver's seat and adjust the steering column lever to position "A". This will allow the steering column to be secured. It is not safe to make adjustments while the equipment is moving. You should choose the most convenient angle of the steering column so that the driver can work comfortably. To do this, the lever is moved to position “B”, the optimal angle of inclination is selected, the handle returns to mode “A” and the selected position is fixed.

Parking brake

To park the forklift, the wheels must be blocked. To block the 2 rear (usually) wheels, the lever is pulled towards itself. To release the parking brake, the release button at the top of the lever is pressed and held, and then the lever is moved forward.

Carriage lift lever

Before operating the forklift, it is important to ensure that no one is nearby. To raise the forks, pull the carriage lift lever towards you. To lower the forks, the handle must be moved to the forward position. The lifting speed of the attachment is adjusted by changing the tilt of the lever, engine speed, and pressing the accelerator pedal. You can speed up or slow down the lowering of the forks only by changing the angle of the lever. The number of revolutions of the loader engine does not affect the speed of lowering the forks.

Tilt lever

Before working with equipment, it is important to make sure that there are no people nearby. To tilt the mast back, the tilt lever is moved back. To change the direction of the mast and move it forward, the handle is set to the forward position. You can change the speed of movement of the mast using the tilt lever and the gas pedal.

When the engine is not running, it will not be possible to tilt the mast forward, because the tilt lock on the control valve is activated. If you press the lift lever while the forklift engine is not running, the forks will lower forward.

Inching pedal

The inching pedal for an automatic transmission is designed for use during high-speed operation. Lightly pressing the pedal reduces the hydraulic clutch pressure. When the pedal is pressed all the way, the clutch is completely disengaged and the braking system is activated. It is not allowed to turn on “slow travel” to slow down the equipment when going down or going up a slope, because the clutch will be disconnected, which will make engine braking impossible. Refer to your forklift owner's manual for more information on how to operate the crawl pedal.

Brake

To slow down the movement of special equipment, press the brake pedal. When pressed, the brake lights come on.

Accelerator

You can speed up the movement of the forklift by pressing the gas pedal. When you release pressure on the accelerator pedal, the forklift engine starts to idle. On gasoline models, a manual or automatic choke is used to start the loader in cold weather.

Forklift Controls and Productivity

Loaders rightfully hold the title of the most versatile type of equipment. The range of work they perform is so wide that today it is difficult to imagine a large warehouse or construction site without their operation. In addition, their scope of application covers agriculture, public utilities, and industrial facilities. They are capable of working in enclosed spaces, negotiating narrow spaces, entering hard-to-reach places, operating smoothly at high and low temperatures (from -30 to +40 °C), lifting and transporting heavy loads. This miracle of technology today is one of the most in demand on the vehicle market, both for purchase and for rent.

The main factor behind the popularity of forklifts is ease of operation. Despite the fact that to operate this type of transport it is necessary to undergo special training, in real life you can master it yourself. Understanding which lever (joystick, sensor, pedal, etc.) is responsible for what is easy on an intuitive level. But we in no way call for abandoning specialized training. Without the help of professionals, you will never achieve the desired level of safe and productive operation.

Forklift Control System

Loader interior

This is what the controls of these special vehicles consist of:

1. Egnition lock. Anyone who has ever traveled on any type of transport is familiar with it. Three positions - Off, On, Start - speak for themselves, no explanation required. The only note: never leave the key on the On mark if the engine is not running. Otherwise, you may be in for an unpleasant surprise in the form of a dead battery.
2. Steering wheel. It is equipped with a special handle that simplifies the operation of the loader and makes it more comfortable. Below it is a lock handle for adjusting the tilt. It allows you to set the steering wheel in the most comfortable position.
3. Sound signal. As in most cases, it is located in the center of the steering wheel.
4. Reverse and gearshift handles (for special equipment with a manual transmission). The selector, which is responsible for the direction of movement, has three positions: forward (F), neutral (N), reverse (R). Special equipment most often has only two speed modes: high (2) and low (1). Plus neutral position.

Important: in some modern loader models the control algorithm may be different. Before use, carefully inspect the handle of the lever itself. A usage diagram is often depicted there.

1. Drive switch (for vehicles with automatic transmission). Adjusts forward (F) and reverse (R) movement. The central location is neutral (N), at which the engine starts.
2. Light switch. It is combined, responsible for all lighting devices at the same time. There are three marks on it: Off – near – far. To switch, you just need to set the lever to the desired position. It also includes turns (L – left, handle forward, R – right, position backward).
3. Parking brake (aka handbrake). To activate it, pull it back as far as it will go. It is fixed automatically. To return to the original position, you need to press the button located on the same lever and lower it.

Remember: if the warning buzzer goes off, it means you were too slow or forgot to set the parking brake.

1. Pedals:

• accelerator (gas). Serves to adjust the speed mode by pressing;
• brake. Used to decelerate or come to a complete stop;
• clutch (for vehicles with manual transmission). Used to change speeds;
• slow speed (for cars with automatic transmission). Suitable for driving in low gear and low speed.

1. Handles:

• control for lifting the forks (to lift, you need to set it in the rear position, to lower it, you need to set it forward);
• adjusting the tilt of the mast (tilt it forward - the lever forwards, backwards - the same).

It is important to note that these are the basic forklift controls. Many manufacturers make some changes to the design, improve the machines, and add different devices. For example, in the cabin of Toyota special vehicles there is an armrest on which a five-lever control panel is located. With its help, you can perform several manipulations simultaneously without compromising operator comfort. If you want to improve your car, the certified Snabavto online store provides this opportunity. Here you can buy spare parts for forklifts from Toyota, Caterpillar, Jungheinrich, Komatsu, Manitou and other brands. Everything that will make operating equipment more convenient and efficient is on the shelves today. Before you get behind the wheel, we recommend that you read the manufacturer’s instructions in detail.

Levers VS joysticks

Everyone who has been working on a loader for years knows the “charms” of each control system and, most likely, has chosen their favorite.

Both lever and joystick controls require specific skill and experience. How are they different? Their features are in the table:

A forklift's controls are what have the greatest impact on operator productivity and performance. If switching and adjusting components do not cause stress, do not require extra labor, do not force you to think long and be distracted by searching for the right sensor, then the driver can fully concentrate on performing direct tasks. Any system must have logic. The speed and quality of work depend on it.

Joystick control technique

The joystick is located in the loader cab to the right of the driver.

Forklifts are controlled using a joystick as follows:

• for lifting - point the handle towards you;
• to lower - push the joystick away from you;
• loading movement of the bucket (raking) - handle to the left;
• releasing the bucket from the load - moving the handle to the right.

The joystick control system is extremely easy to learn. In some modern models, the control unit includes a mobile joystick. This is convenient for the operator who will perform the work with his left hand - the handle is installed on the left side. This greatly simplifies the operation of mini-loaders, and operators save effort - just put your hand on the joystick, while keeping your shoulders and arms practically relaxed.

To ensure safe operation of the equipment, before starting the engine, you need to make sure that the machine is in good working order, check its technical readiness for work - the level of coolants, oil, brake fluid, fuel level, charging the electric forklift battery. Be sure to check the operation of the brake and clutch pedals, parking brake, gear shift lever, serviceability of the turn-on elements, sound and light signals.

Forklift Safety Basics

To safely drive any vehicle, knowing the basic rules is not enough. Unforeseen situations always arise during which you need to remain calm and confident. When driving a forklift every day in familiar conditions, you should not lose vigilance and relax.

1. When moving a forklift, first of all remember to place the forks in the correct transport position (approximately 10-20 cm above the ground) and tilt the rear mast. It is strictly forbidden to move equipment with raised forks.
2. In order for the forklift to safely climb an incline, a series of steps must be performed: press the service brake pedal, release the parking brake, and then, while gently pressing the accelerator pedal, slowly release the service brake.
3. If the forklift is moving on sloping terrain, it is recommended to avoid stopping and loading. This is dangerous due to the change in the center of gravity of the loaded equipment.
4. Forklifts should not carry loads that exceed their maximum lifting capacity. It is also strictly prohibited to use these vehicles to transport people.
5. It is necessary to ensure that the center of gravity of the transported cargo is located correctly. This will prevent the load on the pallet from moving or causing dangerous tipping.
6. It is equally important that the operator holds the steering wheel securely when driving the forklift and does not leave his workplace until the engine is completely turned off.

Attachments

In most cases, the main attachment of a loader is a bucket. It is used for loading bulk cargo, moving, and storing. However, if necessary, special equipment can be supplemented with a fork part. The forks allow you to conveniently work with tared and palletized loads. Most forks are designed to move loads in an up/down direction. However, there are also models with a telescopic boom that can extend several meters forward. But even in such multifunctional options, ease of control of the loader is ensured. To operate equipment, you must have a state-issued “forklift operator” certificate with the required categories.

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Learning to ride

1. First of all, before you get behind the wheel, you need to know how to start and how to control the vehicle. Basically, the principle of its operation is very similar to driving a regular car, and if you already have such skills, this will help you a lot.
2. First, try driving the forklift just like that, without a load or other equipment. You have to get used to controlling it and feeling it.
3. When you have mastered the basics of control, you can begin to study the basic functions of your device. Forklifts have special levers near the steering wheel that allow you to move the fork in several planes. To do this, practice working with them. If you have a wooden pallet, then you can carry it around, learn how to pick it up or put it down.
4. When you already feel confident, you can try moving oversized cargo. However, you should never rush, as this can be dangerous both for your health and the health of others.

Develop your driving skills gradually and never immediately take on an impossible job that you have not done before. Although sometimes from the outside it even seems like a very simple task.

It is also important to follow safety precautions and be careful not to cause harm.

Theoretically, you can learn to drive a forklift thanks to this video:
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How to Operate a Bobcat Skid Loader

Driving a forklift takes 2 to 4 hours. Training should include the following steps. Inspection of the car. The trainee walks around the loader from all sides, trying to notice any malfunctions. Before allowing the trainee to take the driver’s seat, pay his attention to the general condition of the components and assemblies of the machine (forks, tires, engine), and the cleanliness in which they are kept. Refer to the symbols for the forklift's lifting capacity and the load's center of gravity. Pulling away. Emphasize the importance of starting safely. First of all, point out the need to put the controls in neutral and release the brake. Show how to start the engine, then have the student do it. Teach him how to check and use the horn, steering wheel, lifting and tilting mechanisms, lights, brakes, etc.). Give the student the opportunity to perform these operations himself. For the tilting mechanism of the forklift, first show how to move the lifting mechanism, then tilt the forklift as far as possible forward and backward. Emphasize that the operator must ensure that the machine is in good working order every day before starting work. Observe the operator as he performs this duty during training and then in practice. Control. Explain that the weight of the load is distributed over the front axle of a counterbalanced forklift, causing the rear wheels to turn. Let the trainee feel the steering. Emphasize that vertical runout of the rear wheels indicates that the fork load is too heavy. This may make the forklift difficult to operate and may even cause you to lose control. Practical driving. Pay attention to the trainee that the fork must be at a height of 5 cm from the floor before starting movement. Practice moving away smoothly, without jerking. Have the trainee check the reliability of the brakes. Tell them to plan their actions in advance and avoid decisions made at the very last moment. Develop the skill of keeping your distance from shelves, walls, and containers. Explain that the forklift should not be stopped using the reverse mechanism (this will cause sudden overload of the engine and transmission and their premature failure). The student independently performs exercises on crossing the main passage, maneuvering in dead-end passages, entering and exiting passages (without a load). Pay attention to the use of a sound signal (at intersections, when there are people or cars in the driveways). Emphasize that error-free driving is only possible through constant observation and concentration in front of you. Make the trainee aware of the need to monitor the technical condition of the forklift during the shift. Actions in times of extreme danger. Fire on an electric forklift. Explain the rules of fire behavior, then have the trainee perform practical actions: stop the machine immediately, turn off the power, leave the cab, disconnect the battery, get a fire extinguisher on the forklift, or use a nearby fire extinguisher. Explain that in a real fire, the operator must extinguish the flame and report the fire to the foreman and safety engineer. Fire on a forklift running on liquefied gas. The trainee must immediately turn off the ignition, stop the car, leave the cab, clear the passage of people and extinguish the flame with a standard fire extinguisher or a fire extinguisher located nearby. The fire must then be reported to the foreman and safety engineer. Spontaneous movement of the loader (throttle valve or accelerator pump valve stuck). Explain that you need to brake the car and disconnect the battery, then inform the technician and repair personnel about the incident. The student practices disconnecting the cable. Non-stop vertical movement of the loading body (the hydraulics have failed and the fork continues to rise). Explain that the operator must immediately leave the cab and disconnect either the battery cable or the battery-mounted emergency lever. The student performs a practical exercise. Emphasize that the operator must then notify the technician and maintenance personnel. Moving cargo. The trainee practices maximizing the spread of the forks and holding them at a height. The forklift must approach the load slowly and straight ahead. The trainee performs exercises to move forks under a container or pallet until the load rests on the forklift. The trainee, acting on the controls of the lifting and tilting mechanisms of the forklift, performs exercises on placing the load on the pick-up, tilting the forklift back to the limit and adjusting the position of the load at height. Emphasize the need to inspect the load before placing it on the fork. The cargo must be in a safe condition. Show the student several weights: stable and unstable. Ask which loads, in his opinion, can be lifted and which cannot. Emphasize that you should not lift a load without ensuring it is stable. The trainee is practicing an exercise in operating a forklift in conditions where a large load makes it difficult for the operator to see in front of the forklift. Prompt the trainee to turn the forklift around and drive in reverse (the driver turns around and faces the direction of travel). The trainee performs an exercise on moving with a load of railway tracks or other irregularities on the road. Draw his attention to the need to move over the obstacle at an angle, hitting it with one wheel each time. The trainee practices driving a forklift with a load on work sites. When moving along a ramp, he learns to hold the load in an inclined position, otherwise the load may fall off the pickup. The trainee practices the exercise of descending the ramp in reverse, while the load is in an inclined position; masters the techniques of unloading a vehicle. Instruct the trainee to block the car wheels, securely fasten the flooring, and inspect the condition of the car body floor. Emphasize the dangers of driving onto oily decking. Have the trainee make sure there are no obstacles on the work site and check the height of the body doors. The gap between the top edge of the door and the load hoist must be at least 5 cm. The wheels of railway cars must also be blocked on both sides. Parking. The trainee practices the exercise of parking the forklift in the permitted places. Make sure he remembers to set the parking brake, lower the forks so that the forks rest on the floor, put the levers in neutral and turn off the power. When parking on a slope, it is recommended to place chocks under the wheels. General remarks. Point out to the trainee that the professional operator considers it his responsibility to master perfectly the driving techniques that were practiced in the courses. Internship. It takes from two hours to two days. It is recommended that the trainee be under the supervision of his immediate supervisor at all times. Such control is carried out sporadically by the course administration. Final comments. It is necessary to constantly remember the main goal of the courses - to develop in the operator the ability and skills to safely operate a forklift and handle cargo, a “professional” attitude towards work and a desire to perform it flawlessly.

What licenses are needed for a forklift?

Gostekhnadzor authorities are responsible for obtaining rights to work as a loader. All vehicles belonging to the “tractor” category are under the competence of this particular department. Therefore, the license to operate a loader also has its own name - a tractor driver’s license; it will indicate “forklift operator”.

Direct training takes place in a certified driving school that specializes in training such drivers.

Pulling away

1. Follow these steps for forklifts with TORQFLOW clutch and transmission.
• Loaders with clutch

Fully depress the clutch pedal and move the travel direction selector (forward/reverse) (1) to the forward [ 1 ] (F) or reverse [O] (R) position, and the speed selector (2) to the [1] (Low) position broadcast).

NOTE

Before switching the travel direction and speed selectors to position, you must fully depress the clutch pedal.

• Loaders with TORQFLOW transmission (automatic transmission)

Press the crawl pedal and move the forward/reverse selector lever to the forward (F) or reverse (R) position.

2. Return the parking brake lever forward to the release position. (Parking brake released) NOTE

• Driving with the parking brake applied will result in overheating and brake failure. This also leads to accelerated wear of the brake linings. • If the forklift has been driven for a long distance in this condition, contact your Komatsu Forklift distributor/dealer.

3. Make sure there are no obstructions to traffic. 4. The loader will begin to move when the clutch pedal or trolling pedal is smoothly released while simultaneously pressing the accelerator pedal. As soon as the loader starts moving, release the clutch pedal or trolling pedal. NOTE

Do not rest your foot on the clutch pedal, crawl pedal or brake pedal unless necessary.

Loader control in ISO and H modes

The left joystick controls the movement of the Bobcat Loader in ISO mode. Straight-line movement of the lever leads to a similar movement of the equipment. Simultaneously moving the joystick to the right or left allows you to give a command to turn. A turn in place is performed by moving the lever to the side without moving forward or backward.

The right joystick is used to control the working parts. This lever is used to raise and lower the boom and tilt the bucket forward or backward. With practical experience, these operations are performed accurately and accurately.

Control of equipment in H mode is performed using two joysticks simultaneously. The operator works with levers as pedals in the first version. There is the possibility of rectilinear and directional movement, turning on the spot. The left joystick is used to control the boom. The operation of the bucket is controlled by the right lever.