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FORKLIFT OPERATOR MANUAL
SECTION TITLE
Introduction
Accident Identification
Economic Losses Due to Accidents
Student Outline Workshop
Vehicle Condition
Safety Equipment
Personnel Safety
Vehicle Misuse Or Abuse
Starts and Stops
Load Handling
Traveling
Stacking and Unstacking
Bridge Plates
Working Highway Trailers
Parking
Gasoline Or Diesel Oil Units
LP Gas Units
Electric Units
Liquid Propane
20
21
22
23
15
16
17
18
9
10
11 & 12
13 & 14
4
5
2
3
6
7
8
3/98
1

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, don’t hesitate to consult with your supervisor.
2

5.
4.
Part 1.
2.
3.
Accident: Definition
An unplanned event or series of events that cause property damage, injury, or death.
Causation:
All accidents are caused Unsafe conditions and unsafe acts.
Forklift Fatality Accidents 1991-1992
How accidents occurred Number
Forklift Overturned.....................................41
Forklift struck something, or ran off dock..13
Worker pinned between objects..................19
Worker struck by material..........................29
Worker struck by forklift............................24
Worker fell from forklift.............................24
Worker died during forklift repair...............10
Other accidents...........................................10
Total...............................................170
1. Vehicle conditions
2. Floor conditions
3. Floor construction
4. Housekeeping in the travel ways
5. Equipment guarding
6. Ramps
7. Dock conditions
8. Blind corners
9. Congested areas
10. Types of loads transported
1. Operating to fast
2. Overloading the equipment
3. Stacking unsafely
4. Failure to follow accepted procedures
5. Operating known defective equipment
6. Unawareness of hazards
7. Failure to check dock plates
Percent
24
8
11
17
14
14
6
6
100
Accident Percentages in 1989
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.
Unsafe conditions are identified as the following:
Unsafe Acts are identified as the following:
3

Part 3.
Part 4.
Part 1.
Part 2.
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 a 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.
Employee Income Reductions
In an average year, employees in industry lose approximately 5 Billion dollars through direct income reductions due to accidents.
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.
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.
4

8.
1.
2.
Fill in the correct word or words that complete the sentence.
Load center distance is measured from . to the center of the load.
The pivot point of a counter balanced fork - lift truck is the .
.
When ascending or descending ramps or grades, loaded trucks shall be driven with the load . .
3.
4. floor.
5. should
When traveling with a load, the forks should be . to . inches off the
When entering a door way or proceeding through a blind intersection you use the . as a warning device.
If a load obstructs the operator’s vision, then he or she shall travel in
7.
6.
.
The OSHA rule for a parked internal combustion engine fork - lift truck is:
Fork Tips on the
Shift lever in
Parking Brake
Engine
.
.
.
.
Before entering a disconnected highway trailer at the loading dock, the operator shall check for the following:
A. .
B. .
C. .
D. .
9.
10.
11.
12.
13.
14.
Overloading a fork - lift truck will raise the . . off the floor.
Choking the wheels of a over the road trailer at the loading dock is the responsibility of the .
The OSHA rule states that no lift truck traveling in the same direction shall be
. by another powered industrial truck in a hazardous traffic area.
Load capacity and load center distance is displayed on the
.
Tilting the mast back the load center distance.
The center of gravity of a fork - lift truck is located. .
5

Part 1 adversely
Part 2.
Part 3.
Fork - lift trucks must be inspected before and during each shift and must not be used if the inspection reveals any condition which might affect the safety of the vehicle, its operator or others.
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.
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.
6

Part 1. a. b. c. d. e.
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.
All lift - trucks should be equipped with a horn or other audible warning device, which can be distinctly heard above the general background noises.
All lift - trucks should be equipped with a dry chemical fire extinguisher.
An overhead guard must be used as a protection from falling objects.
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.
A load backrest extension should be used whenever necessary to minimize the possibility of a load or any part of it from falling rearward.
7

Part 1.
2.
3.
4.
5.
6.
7.
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.
Never drive with wet or greasy hands.
Your hands, arms, feet, and legs must never be placed between the uprights of the mast or outside the running lines of the vehicle.
Never engage in horseplay while operating a truck. Practical jokes have been known to kill people.
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 operator’s compartment.
Operation of any of the control levers on your truck from a position other than the driver’s seat is prohibited.
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 purposes. The driver must remain in control of the vehicle while the employee is elevated. handrails and firmly secured to the load carriage, may be used for such
8.
9.
10.
11.
12.
13.
14.
Do not allow internal combustion engines to run idle for long periods inside a building, railroad cars, or trailers.
Never allow any person to stand or pass under the elevated portion of any fork - lift truck, loaded or empty.
Always make sure that pedestrian helpers are in the clear.
Always be familiar with hazards of the material you are handling.
It is recommended that you wear safety shoes.
Wear gloves when you handle materials, fuel cylinders, pallets etc. manually.
If a CO - worker is injured, assist him to First - Aid and report the incident to your supervisor.
Section VIII Vehicle Misuse or Abuse
8

Part 1.
2.
3.
4.
5.
6.
Section IX
Your lift truck must never be used as a jack to lift heavy machines or other heavy objects, without special permission of your supervisor.
Never use your truck, or its forks, as battering rams.
Lift - trucks must not be used for opening or closing the doors of railroad freight cars or trailer trucks.
Never tow or push a railroad car with a fork - lift truck.
Never use your truck with another in a combined lift, unless specifically authorized to do so by your supervisor.
Never push another vehicle in order to get it started.
Starts and Stops
9

Section X
Part 1.
Part 1.
2.
3.
4.
5.
Never start to move your vehicle, in either direction, until you have checked to see that your path is clear.
Avoid sudden starts. A vehicle going in sudden motion might strike a fixed object or and unsuspecting bystander.
Avoid sudden stops. A quick stop is and easy way to lose all or part of a load.
Never step out of your truck until it has come to a complete stop.
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.
Load Handling
Know the rated capacity of your truck in terms of load weight and load center distance. These essential details are always shown on the manufacturer’s name plate.
10

2. Never load your truck beyond it’s rated capacity.
3.
Accessories are
A lift - truck which is equipped with accessories on the hoist assembly is already partially loaded and, therefore, can’t carry as much of a payload. fork - extensions, load adjusters, boom crane attachments, drum clampers, etc.
4 When 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.
6.
7.
8.
Remember that the lifting capacity of your truck is decreased substantially when the load center is greater than that shown on the nameplate.
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.
Never allow anyone to sit or stand the counter weight in order to increase the lifting capacity of your truck.
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.
10.
11.
Before attempting to lift a load, be sure that it is stable and properly balanced on the forks.
Pick up each load squarely and well balanced, to avoid tipping the truck or shifting the load.
Use special caution when handling off - centered loads.
12.
13.
Place the forks as far as possible under every load, the tilt the mast back just far enough to stabilize the load.
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.
Section X
When you must transport compressed gas cylinders, make sure they are properly capped, placed in a vertical position, and secured to the truck.
Load Handling (Continued)
Part 16. Never transport gas-welding carts on your lift - truck.
11

17.
18.
Section XI
Part 1.
Never attempt to lift damaged pallets or crates if a hazard will be created as a result of their faulty condition or position.
Don’t use defective pallets. Replace them with good ones.
Traveling
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.
12

a
2.
3.
4.
5.
6.
7.
8.
9.
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.
Other vehicles, traveling in the same direction, must not be passed at intersections, blind spots, or other dangerous locations.
The right of way must be yielded to any emergency vehicles.
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.
Use “oil - dry”, or a similar absorptive substance, on oil and grease spills. Report major spills to your supervisor.
Where specific paths are marked off for fork - lift traffic, stay within the established boundaries.
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.
Your truck must always be operated at a speed which permits it to be brought to 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.
Part 17. 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.
13

of
19.
20.
21.
Watch for the unpredictable movements of pedestrians and of other vehicles.
Always give warning when you approach anyone from the rear.
Use your horn only as a warning to others, not as a demand for the right of way.
22.
23.
24.
Always stop at railroad crossings and check for moving railroad equipment.
Cross railroad tracks diagonally, whenever possible.
Always drive your truck on hard surfaced roadways. Never drive your truck over sidewalks, temporary trench covers, plank-covered excavations etc.
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.
25. Fork - lift trucks must not be operated in areas with insufficient headroom under lights, pipes, sprinkler systems, and other overhead obstructions.
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 roadways, where soft shoulders may be present.
30.
31.
Fire aisles, access to stairways, and access to all forms of emergency equipment must be kept clear at all times.
All accidents must be reported to your supervisor promptly.
Part 1. Be sure there is sufficient headroom when you elevate a load.
14

2.
3.
4. pallets.
5. and be
6.
7. load
8.
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.
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.
Place each pallet of material squarely in position and in accurate vertical alignment. Make sure that packages are positioned correctly on the
Excessive overhang might result in damaged goods or a spilled stack.
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.
When approaching or leaving a stack and you must make a turn, due to either aisle or other conditions never turn with the load elevated. All turns must made with the load as low as possible.
Bring a descending load to a slow smooth stop. A sudden stop might cause the machine to tip forward.
Never raise the load while turning into the stack. Make the turn then raise the into position.
Part 1. Bridgeplates, adjustable loading docks and mobile ramps must be in safe condition and must be properly secured in position.
15

2.
3.
When non standard bridge plates must be used, make sure they are securely fixed in position.
Dock boards or bridge plates must be driven over carefully and slowly and their rated capacity must never be exceeded.
Part 1. 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.
16

2.
3.
“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.
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 used as a support in the position closest the rear of the trailer. A “A” frame can be under the rear of the trailer in place of moving the wheel assembly.
5.
6.
7.
Before driving the fork - lift truck into the trailer, check for floor strength of the trailer.
Enter and leave trucks and trailers slowly and carefully.
Check the dock plate to insure that it is secure.
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.
17

2.
3.
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.
Never park in restricted parking zones, on established pedestrian walkways or in front of fire exits, or fire fighting equipment.
4.
5.
6.
Never park a vehicle in gear. Always use the parking brake.
Always “center” the turning wheels when parking your truck.
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.
8.
Parking closer than eight feet from the centerline of a railroad track is prohibited.
Forklift trucks must not be parked near sources of heat, open flames, or similar sources of ignition.
9. fuel supply
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 valve at the cylinder and then run the engine until the fuel in the line is exhausted.
Part 1.
Refueling of gasoline or diesel powered trucks, indoors is strictly prohibited.
18

2.
3.
4.
5.
6.
Part 1.
Fuel tanks must not be filled while the engine is running. Spillage of fuel must be avoided.
Spillage of oil or fuel must be carefully washed away or completely evaporated before the engine is started.
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)
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.
Company rules for refueling may vary, check with your supervisor for specific rules.
If necessary, lift trucks powered by LP gas may be refueled indoors provided that established procedures for changing cylinders are followed in detail.
19

2.
3.
4.
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.
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.
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. collar 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
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. storage
5. on an cylinder g. Never smoke while you are refueling a lift truck or handling L.P. Gas
cylinders.
If a lift truck should run out of fuel at a location remote from the cylinder area, never attempt to transport a cylinder loosely on the bare forks, or strapping the cylinder ordinary pallet. A hand truck should be provided for this purpose. The shall be transported in the upright position and a means of to the hand truck shall also be provided.
Part 1.
Battery charging facilities must be located in areas designated for that purpose.
20

2.
3.
4. when
5.
6.
7.
8.
9.
10.
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.
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.
A conveyor, overhead hoist, or equivalent handling equipment must be used handling batteries.
Reinstalled batteries must be properly positioned and secured in the truck.
A carboy tilter or a siphon must be must be used when handling electrolyte.
Battery recharging and replacing procedure must be posted in the charging areas.
When filling batteries, acid must be poured into water:
Water must never be poured into acid.
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.
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 XIX
Part 1.
Liquid Propane
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.
21

2. dissolve in
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 many other materials.
3.
4. will
5.
6.
7.
A cubic foot (7.5 gal.) of liquid will vaporize into about 270 cubic feet of vapor.
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.
Explosive limits are between 2.3% and 9.5% vapor to air mixture present and explode or burn if ignition is present.
All liquid LP-Gas is at 300-PSI pressure in fuel tanks.
Never fill a cylinder beyond 80% capacity. in
8.
9.
Check all connection for leaks.
Make sure protective caps are in place.
10. Never use the cylinder gauge as a guide when filling a cylinder. the
11. In the event of spillage during the changing of cylinders, take the time to open 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 the fire alarm and clear the area.
X = UNSAFE ACTION O = INCORRECT ACTION C = CORRECT ACTION
22

LOAD PICK UP
Fork Entry
Other
Pallet Movement
LOAD TRANSPORT
Mast Tilt
Load Height
Speed
Horn
Other .
STACKING LOAD
Placing Load
Mast Tilt
Fork Exit
Other
STACKED LOAD PICK UP
Park Brake
Mast Tilt
Fork Entry
Other
.
.
.
.
.
.
.
SPOT PLACEMENT
Front Line
Back Line
Other
VEHICLE SHUT DOWN
Mast Tilt / Forks Down
Transmission Neutral
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) / / .
23