Forklift OPERATOR MANUAL
FORKLIFT OPERATOR SAFETY MANUAL
SECTIONTITLE
IIntroduction2
IIAccident Identification3
IIIEconomic Losses Due to Accidents4
IVVehicle Condition5
VSafety Equipment6
VIPersonnel Safety7
VIIVehicle Misuse or Abuse8
VIIIStarts and Stops9
IXLoad Handling10 & 11
XTraveling12 & 13
XIStacking and Unstacking14
XIIBridge Plates15
XIIIWorking Highway Trailers16
XIVParking17
XVGasoline or Diesel Oil Units18
XVILP Gas Units20
XVIIElectric Units21
XVIIILiquid Propane22
Section I
INTRODUCTION
This manual contains basic rules for the safe operation of
powered fork-lift trucks. These rules have served as the foundation
of operator training programs in all types of industry. They are
based on knowledge and experience gained over a long period of time
by the manufacturers and users of fork-lift equipment.
A fork-lift truck is a valuable work saving device. Once you
have become thoroughly acquainted with its versatile features, you
will find that it is a reliable friend; always ready to obey your
orders. It will easily do jobs, which years ago, required a great
deal of muscle power and time.
A fork-lift truck is never dangerous by itself. Only faulty
handling and lack of care will introduce hazards into its
operation. The following pages contain specific regulations which
when followed at all times, will assure safety for yourself and
others.
In practice, you are likely to be faced with situations that
might not be covered in detail in this manual. That is when your
good judgment becomes especially important. Be alert for changing
conditions and adjust your operations accordingly. If you encounter
special problems, dont hesitate to consult with your
supervisor.
Section II: Accident Identification
Part 1.Accident: DefinitionAn unplanned event or series of
events that cause property damage, injury, or death.
2.Causation:All accidents are caused unsafe conditions and
unsafe acts.
3.Forklift Fatality Accidents How accidents occurredForklift
OverturnedForklift struck something, or ran off dockWorker pinned
between objectsWorker struck by materialWorker struck by
forkliftWorker fell from forkliftWorker died during forklift
repairOther accidents
Pedestrian injuries are the highest volume and percent of the
total.This type of accident accounts for 20%. Tip over accidents
account for approximately 18% of the total. Struck by load is the
third highest volume falls and Strains are the fourth highest.
4.Unsafe conditions are identified as the following:1. Vehicle
conditions2. Floor conditions3. Floor construction4. Housekeeping
in the travel ways5. Equipment guarding6. Ramps7. Dock conditions8.
Blind corners9. Congested areas10. Types of loads transported
5.Unsafe Acts are identified as the following:
1. Operating to fast 2. Overloading the equipment3. Stacking
unsafely4. Failure to follow accepted procedures5. Operating known
defective equipment6. Unawareness of hazards7. Failure to check
dock plates
Section III: Economic Losses
Part 1.Employee Losses
Any disabling injury accident for any employee is a major
financial hardship. A long term disability is especially difficult
in coping with the income reductions that follow, in addition to
the pain of injury recovery.
The family is like any small business, it must have an income in
order to pay the day to day expenses of the family unit. The minute
this income is reduced for any reason, then the family has to
adjust. This adjustment may be minor but it also may be major and
the long term prospects of the family goals may be put in
jeopardy.
Part 2.Employee Income Reductions
In an average year, employees in industry lose approximately 5
Billion dollars through direct income reductions due to
accidents.
Part 3.Business Losses
Accidents are a drain for any business and can be very severe,
if safety is not an important part of the daily operations. The
cost of accident recovery, and administration time can mount up
dramatically.Accident losses in industry in the United States each
year exceeds 33 Billion dollars.
Part 4.Fork - lift Accidents
Fork - lift accidents represent 10% of the above cost figures.
Accidents involving fork - lift operations can result in not only
injuries, but can be measured in the cost of equipment repair,
replacement or direct finished product damage.
Section IV: Vehicle Condition
Part 1Fork - lift trucks must be inspected before and during
each shift and must not be used if the inspection reveals any
condition which might adversely affect the safety of the vehicle,
its operator or others.
Part 2.Any fork - lift truck that emits hazardous sparks or
flames from the exhaust system must be removed from service
immediately and must not be returned to service until the cause for
the emission of such sparks and flames has been eliminated.
Part 3.All repairs to fork - lift trucks must be made only by
authorized maintenance personnel. Documentation of all service on
vehicles, should be kept on file for reference purposes.
Section V: Safety Equipment
Part 1.The fork - lift trucks must be equipped with certain
accessories to assure a greater measure of safety for all
personnel. The accessories listed below are required and
recommended for all trucks.
a.All lift - trucks should be equipped with a horn or other
audible warning device, which can be distinctly heard above the
general background noises.
b.All lift - trucks should be equipped with a dry chemical fire
extinguisher.
c.An overhead guard must be used as a protection from falling
objects.
d.Every lift truck used during the hours of darkness or for
entering dimly lit trailers, railroad cars, warehouses, etc. must
be equipped with adequate headlights. Lights should be mounted both
in the front and rear.
e.A load backrest extension should be used whenever necessary to
minimize the possibility of a load or any part of it from falling
rearward.
Section VI: Personnel Safety
Part1.Only authorized drivers are permitted to operate fork -
lift trucks. Trainees should be permitted to operate trucks only
when they are under the immediate supervision of an approved
trainer or supervisor.
2.Never drive with wet or greasy hands.
3.Your hands, arms, feet, and legs must never be placed between
the uprights of the mast or outside the running lines of the
vehicle.
4.Never engage in horseplay while operating a truck. Practical
jokes have been known to kill people.
5.No one is permitted to ride as a passenger on any part of the
truck unless a safe place to ride has been provided in the
operators compartment.
6.Operation of any of the control levers on your truck from a
position other than the drivers seat is prohibited.
7.The bare forks, or an ordinary pallet, must never be used to
elevate personnel, or to serve as a elevated platform. A special
pallet, fitted with handrails and firmly secured to the load
carriage, may be used for such purposes. The driver must remain in
control of the vehicle while the employee is elevated.
8.Do not allow internal combustion engines to run idle for long
periods inside a building, railroad cars, or trailers.
9.Never allow any person to stand or pass under the elevated
portion of any fork - lift truck, loaded or empty.
10.Always make sure that pedestrian helpers are in the
clear.
11.Always be familiar with hazards of the material you are
handling.
12.It is recommended that you wear safety shoes.
13.Wear gloves when you handle materials, fuel cylinders,
pallets etc. manually.
14.If a co - worker is injured, assist him to First - Aid and
report the incident to your supervisor.
Section VII: Vehicle Misuse or Abuse
Part1.Your lift truck must never be used as a jack to lift heavy
machines or other heavy objects, without special permission of your
supervisor.
2.Never use your truck, or its forks, as battering rams.
3.Lift - trucks must not be used for opening or closing the
doors of railroad freight cars or trailer trucks.
4.Never tow or push a railroad car with a fork - lift truck.
5.Never use your truck with another in a combined lift, unless
specifically authorized to do so by your supervisor.
6.Never push another vehicle in order to get it started.
Section VIII: Starts and Stops
Part1.Never start to move your vehicle, in either direction,
until you have checked to see that your path is clear.
2.Avoid sudden starts. A vehicle going in sudden motion might
strike a fixed object or and unsuspecting bystander.
3.Avoid sudden stops. A quick stop is and easy way to lose all
or part of a load.
4.Never step out of your truck until it has come to a complete
stop.
5.When a fork - lift truck is not in use, the forks must be
fully lowered with the tips of the forks touching the floor. The
controls must be placed in neutral, and the parking brake must be
applied to prevent movement.
Section IX: Load Handling
Part1.Know the rated capacity of your truck in terms of load
weight and load center distance. These essential details are always
shown on the manufacturers name plate.
2.Never load your truck beyond its rated capacity.
3.A lift - truck which is equipped with accessories on the hoist
assembly is already partially loaded and, therefore, cant carry as
much of a payload. Accessories are fork - extensions, load
adjusters, boom crane attachments, drum clampers, etc.
4When attachments are used, particular care must be taken in
securing manipulating, positioning, and transporting the load.
Trucks which are equipped with attachments must be operated as
partially loaded trucks, when they are not handling a load.
5.Remember that the lifting capacity of your truck is decreased
substantially when the load center is greater than that shown on
the nameplate.
6.If the rear end of your truck rises from the floor when you
attempt a lift it clearly indicate that the load is far above the
capacity of the machine.
7.Never allow anyone to sit or stand the counter weight in order
to increase the lifting capacity of your truck.
8.Only stable and safety arranged loads shall be handled. Avoid
carrying loose materials on the forks. Use pallets whenever
possible and make sure that potentially unstable loads are made
secure.
9.Before attempting to lift a load, be sure that it is stable
and properly balanced on the forks.
10.Pick up each load squarely and well balanced, to avoid
tipping the truck or shifting the load.
11.Use special caution when handling off - centered loads.
12.Place the forks as far as possible under every load, the tilt
the mast back just far enough to stabilize the load.
13.Adjust the mast to the vertical position before depositing or
picking up a load.
14.Always keep the mast tilted back slight when transporting a
load. This will keep the load securely against the backrest while
the vehicle is in motion.15.When you must transport compressed gas
cylinders, make sure they are properly capped, placed in a vertical
position, and secured to the truck.
Section IX: Load Handling (Continued)
Part16.Never transport gas-welding carts on your lift -
truck.
17.Never attempt to lift damaged pallets or crates if a hazard
will be created as a result of their faulty condition or
position.
18.Dont use defective pallets. Replace them with good ones.
Section X: Traveling
Part 1.All traffic regulations must be observed, including
authorized speed limits. In some locations, the maximum permissible
speed for a fork - lift truck may be substantially lowered for safe
traffic reasons.
2.A safe distance must be maintained between your truck and any
vehicle you are following. In areas with sharp slopes or other
special hazards, the minimum following distance must be
increased.
3.Other vehicles, traveling in the same direction, must not be
passed at intersections, blind spots, or other dangerous
locations.
4.The right of way must be yielded to any emergency
vehicles.
5.Never drive over objects lying on the floors or roadways.
Driving over scrap lumber, piping, or other such materials will
damage the truck and might easily shift or topple the load.
Potholes or other sharp depressions in the floor or roadway must
also be avoided.
6.Use oil - dry, or a similar absorptive substance, on oil and
grease spills. Report major spills to your supervisor.
7.Where specific paths are marked off for fork - lift traffic,
stay within the established boundaries.
8.When traveling, the load must be raised only as far as is
necessary to clear the travel surface. Six to Ten inches elevation
is normally sufficient.
9.Your truck must always be operated at a speed which permits it
to be brought to a safe stop, under all conditions.
10.When driving on wet or slippery floors, always slow down
enough to maintain full control of your truck.11.Slow down, sound
the horn, and be prepared to stop at cross aisles and other
locations, where vision may be obstructed.
12.When making turns, the speed of your truck must be reduced to
a safe level.
13.Travel in reverse when forward vision is obstructed.
14.When traveling on ramps, trucks must be operated with the
load upgrade.
15.Travel in reverse when driving down a ramp.
16.Grades must be ascended or descended slowly.
Section X: Traveling (Continued)
Part17.On all grades, the load and forks must be tilted back
only to the extent necessary for load stability and for surface
clearance at the outer end of the forks or load.
18.Always look in the direction of travel.
19.Watch for the unpredictable movements of pedestrians and of
other vehicles.
20.Always give warning when you approach anyone from the
rear.
21.Use your horn only as a warning to others, not as a demand
for the right of way.
22.Always stop at railroad crossings and check for moving
railroad equipment.
23.Cross railroad tracks diagonally, whenever possible.
24.Always drive your truck on hard surfaced roadways. Never
drive your truck over sidewalks, temporary trench covers,
plank-covered excavations etc.
25.Fork - lift trucks must not be operated in areas with
insufficient headroom under lights, pipes, sprinkler systems, and
other overhead obstructions.
26.When passing through any doorway, make sure you have adequate
side clearance as well as overhead clearance.
27.Overhead doors must be fully opened before you pass through
the opening.
28.When moving from brightly lit areas into a dimly lit interior
proceed with caution.
29.Maintain a safe distance from the edge of ramps, or platforms
while operating a truck on any elevated dock or platform. Similar
caution is required at the edges of roadways, where soft shoulders
may be present.
30.Fire aisles, access to stairways, and access to all forms of
emergency equipment must be kept clear at all times.
31.All accidents must be reported to your supervisor
promptly.
Section XI: Stacking and Unstacking
Part1.Be sure there is sufficient headroom when you elevate a
load.
2.Don't permit anyone to stand near your lift- truck while you
are placing a load into, or removing a load from an elevated
position.
3.When stacking one pallet load of material on top of another,
always set the top pallet down gently. Dropping a pallet roughly
might damage material on lower pallets and might even lead to stack
failure.
4.Place each pallet of material squarely in position and in
accurate vertical alignment. Make sure that packages are positioned
correctly on the pallets. Excessive overhang might result in
damaged goods or a spilled stack.
5.Extreme care must be used when a load is being lifted or
lowered in a high lift, for this reason the mast should always be
vertical. Never transport a load in a elevated position.
6.When approaching or leaving a stack and you must make a turn,
due to either and aisle or other conditions never turn with the
load elevated. All turns must be made with the load as low as
possible.
7.Bring a descending load to a slow smooth stop. A sudden stop
might cause the machine to tip forward.
8.Never raise the load while turning into the stack. Make the
turn then raise the load into position.
Section XII: Bridge Plates and Other Vehicle Boarding
Devices
Part1.Bridge plates, adjustable loading docks and mobile ramps
must be in safe condition and must be properly secured in
position.
2.When non standard bridge plates must be used, make sure they
are securely fixed in position.
3.Dock boards or bridge plates must be driven over carefully and
slowly and their rated capacity must never be exceeded.
Section XIII: Loading and Unloading Highway Truck Trailers
Part1.The brakes of highway trucks must be set, and wheel chocks
must be placed under the rear wheels, to prevent the trucks from
rolling while they are being boarded by fork - lift trucks.
2.A frame supports must be placed under the front ends of semi -
trailers which are not attached to tractors, in order to prevent
upending during loading or unloading operations.
3.Improvised supports, such as pole - jacks, pallets, drums,
etc. are not acceptable substitutes for the standard A frame
support.
4.Semi - trailers equipped with adjustable rear wheel assemblies
must not be boarded by fork - lift trucks until the rear wheels
have been moved to and secured in the position closest the rear of
the trailer. An A frame can be used as a support under the rear of
the trailer in place of moving the wheel assembly.
5.Before driving the fork - lift truck into the trailer, check
for floor strength of the trailer.
6.Enter and leave trucks and trailers slowly and carefully.
7.Check the dock plate to insure that it is secure.
Section XIV: Parking
Part 1.When a forklift truck is left unattended, the forks must
be fully lowered with the tips touching the floor, the controls
must be in neutral, the power must be shut off, and the parking
brake set.
2.A fork-lift truck is unattended when the operator is 25 feet
or more from the vehicle which remains in his view, or whenever the
operator leaves the vehicle and it is not in his view.
3.Never park in restricted parking zones, on established
pedestrian walkways or in front of fire exits, or fire fighting
equipment.
4.Never park a vehicle in gear. Always use the parking
brake.
5.Always center the turning wheels when parking your truck.
6.Parking a forklift truck on an incline is not generally
recommended and in most areas is strictly prohibited. If parking on
and incline is unavoidable, wheels must be blocked and approved by
your supervisor.
7.Parking closer than eight feet from the centerline of a
railroad track is prohibited.
8.Forklift trucks must not be parked near sources of heat, open
flames, or similar sources of ignition.
9.The fuel supply valve at the cylinder must be closed when a
truck is to be parked more than 15 minutes. If the truck is to
parked overnight, shut off the fuel supply valve at the cylinder
and then run the engine until the fuel in the line is
exhausted.
Section XV: Trucks Powered by Gasoline or Diesel Oil
Part1.Refueling of gasoline or diesel powered trucks, indoors is
strictly prohibited.
2.Fuel tanks must not be filled while the engine is running.
Spillage of fuel must be avoided.
3.Spillage of oil or fuel must be carefully washed away or
completely evaporated before the engine is started.
4.When it is necessary to use anti-freeze in the engine cooling
system only those products having a glycol base shall be used.
(Check the manufacturers manual)
5.Water mufflers must be filled daily, or as frequently as is
necessary to prevent depletion of the water supply to a level below
seventy five percent of capacity.
6.Company rules for refueling may vary, check with your
supervisor for specific rules.
Section XVI: LP Gas Fueled Trucks
Part1.If necessary, lift trucks powered by LP gas may be
refueled indoors provided that established procedures for changing
cylinders are followed in detail.
2.If a quick-closing coupling (a type which closes in both
directions when uncoupled) is used in the fuel system the shut off
valve on the empty cylinder must be closed before the coupling is
opened, and the valve on the full cylinder must remain closed until
the fuel line is securely reconnected.3.If the fuel system is not
equipped with a quick-closing coupling, the shut off valve on the
depleted cylinder must be closed and engine must be allowed to run
until the fuel in the supply line is exhausted.
4.Whenever it is necessary to refuel a lift-truck which is
powered by LP gas, the following precautions must be taken.
a. Check fuel lines and fittings for abnormal wear and any other
condition which could cause leakage.
b. Inspect the quick-closing coupling, to make sure that the O
ring and gasket are in good condition and seated in the proper
place.
c. Examine the full cylinder for damage and leaks.
d. Place the full cylinder in the cradle with the aligning hole
in the cylinder collar placed over the alignment pin on the
vehicle.
e. Lock the cylinder into place by securing the hold down
clamps.
f. After reconnecting the fuel line to the cylinder, open the
liquid service valve on the cylinder very slowly.
g. Never smoke while you are refueling a lift truck or handling
L.P. Gas cylinders.
5.If a lift truck should run out of fuel at a location remote
from the cylinder storage area, never attempt to transport a
cylinder loosely on the bare forks, or on an ordinary pallet. A
hand truck should be provided for this purpose. The cylinder shall
be transported in the upright position and a means of strapping the
cylinder to the hand truck shall also be provided.
Section XVII: Electrical Powered Lift - Trucks
Part1.Battery charging facilities must be located in areas
designated for that purpose.
2.Facilities must be available for the flushing and
neutralization of spilled electrolyte, for fire protection, for
protection charging apparatus from damage by trucks, and for safe
dispersal of fumes from gassing batteries.
3.Where racks are used for supporting batteries, they should be
made of materials which will prevent generation of sparks, or
should be coated or covered to achieve that objective.
4.A conveyor, overhead hoist, or equivalent handling equipment
must be used when handling batteries.
5.Reinstalled batteries must be properly positioned and secured
in the truck.
6.A carboy tilter or a siphon must be must be used when handling
electrolyte.
7.Battery recharging and replacing procedure must be posted in
the charging areas.
8.When filling batteries, acid must be poured into water: Water
must never be poured into acid.
9.When charging batteries, vent caps must be kept in place to
avoid electrolyte spray. Care must be taken to assure that the vent
caps are functioning.
10.Smoking is prohibited in battery charging areas.
11.Precautions must be taken to prevent open flames, sparks, or
electric arcs in battery-charging areas.
12.Tools and other metallic articles must be kept away from the
tops of uncovered batteries.
Section XVIII: Liquid Propane
Part1.Propane, Butane or mixtures of the two are the principle
components of LP-Gas. They are obtained in great quantity from oil
and gas wells and from natural gasoline refinery operations.
2.LP-Gas posses some of the properties of both liquid and
gaseous fuels. They will burn, they will burn, they will vaporize,
they are not corrosive and will dissolve in many other
materials.
3.A cubic foot (7.5 gal.) of liquid will vaporize into about 270
cubic feet of vapor.
4.LP-Gas is heavier than air. This simply means that when
released slowly in still air, more of it tends to go down rather
than up.
5.Explosive limits are between 2.3% and 9.5% vapor to air
mixture present and will explode or burn if ignition is
present.
6.All liquid LP-Gas is at 300-PSI pressure in fuel tanks.
7.Never fill a cylinder beyond 80% capacity.
8.Check all connection for leaks.
9.Make sure protective caps are in place.
10.Never use the cylinder gauge as a guide when filling a
cylinder.
11.In the event of spillage during the changing of cylinders,
take the time to open the engine compartment and air out the
vapors.
12.In the event of a cylinder fire, try to shut off the fuel
valve if possible, and turn in the fire alarm and clear the
area.
FORKLIFT OPERATOR CERTIFICATION EVALUATION
Name : Company : .
Date : / / .
X = UNSAFE ACTIONO = INCORRECT ACTION C = CORRECT ACTION
LOAD PICK UPSTACKING LOAD
Fork Entry Placing Load .Pallet Movement Mast Tilt .Other Fork
Exit Other .
LOAD TRANSPORTSTACKED LOAD PICK UP
Mast Tilt Park Brake .Load Height Mast Tilt .Speed Fork Entry
.Horn Other .Other .
SPOT PLACEMENTVEHICLE SHUT DOWN
Front Line Mast Tilt / Forks Down .Back Line Transmission
Neutral .Other Park Brake .Power / Engine Off .COMMENTS : .
.
( ) Operator Qualified To Operate Forklift Truck
( ) Operator Requires Additional Training
On (Date) / / (Print Name) .
(Social Security Number) - - Was Evaluated For Safe Operation Of
A Powered Forklift Truck.
(Forklift Type) (Mode Of Power) .
(Load Capacity) LBS. (Load Center Distance) INCHES
At the time of evaluation the operator demonstrated the ability
to safely operate the type equipment identified above.
(Signature of Evaluator) (Date) / / .
1