FORKLIFT OPERATOR MANUAL

SECTION

TITLE

Introduction

II

Accident Identification

III

Economic Losses Due to Accidents

IV

Student Outline Workshop

Vehicle Condition

VI

Safety Equipment

VII

Personnel Safety

VIII

Vehicle Misuse Or Abuse

XIX

Starts and Stops

10

Load Handling

11 & 12

XI

Traveling

13 & 14

XII

Stacking and Unstacking

15

XIII

Bridge Plates

16

XIV

Working Highway Trailers

17

XV

Parking

18

XVI

Gasoline Or Diesel Oil Units

20

XVII

LP Gas Units

21

XVIII

Electric Units

22

XIX

Liquid Propane

23

3/98

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
Part 1.

2.

Accident Identification
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.
2

3.

Forklift Fatality Accidents 1991-1992

How accidents occurred
Number Percent
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

24
8
11
17
14
14
6
6

Total...............................................170

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.
4.

Unsafe conditions are identified as the following:

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

5.

Unsafe Acts are identified as the following:

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

Section III

Part 1.

Economic Losses

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
3

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.
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

finished

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
product damage.

Section IV

Student Outline

Fill in the correct word or words that complete the sentence.

1.

Load center distance is measured from

to the center of the load.

2.

The pivot point of a counter balanced fork - lift truck is the

.

3.

When ascending or descending ramps or grades, loaded trucks shall be driven

with the load
.
.

4.

When traveling with a load, the forks should be

4

. to

. inches off the floor.

5.

When entering a door way or proceeding through a blind intersection you should
use the
. as a warning device.

6.

If a load obstructs the operators vision, then he or she shall travel in

7.

The OSHA rule for a parked internal combustion engine fork - lift truck is:
Fork Tips on the
Shift lever in
Parking Brake
Engine

8.

.
.
.
.

Before entering a disconnected highway trailer at the loading dock, the operator
shall check for the following:
A.
B.
C.
D.
.

.
.
.
.

9.

Overloading a fork - lift truck will raise the

floor.

. off the

10.

Choking the wheels of a over the road trailer at the loading dock is the
responsibility of the
.

11.

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.

12.

Load capacity and load center distance is displayed on the

.

13.

Tilting the mast back

14.

The center of gravity of a fork - lift truck is located.

Section V

Vehicle Condition

Part 1

Fork - 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
flames has been eliminated.

sparks and

the load center distance.

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 VI

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.
6

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 VII

Personnel Safety

Part

1.

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
purposes. The driver must remain in control of the vehicle while
employee is elevated.

such
the

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 VIII

Vehicle Misuse or Abuse

Part

1.

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 IX

Part

Starts and Stops

1.

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 X
Part

Load Handling

1.

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.
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.

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.

10

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 X

Load Handling (Continued)

Part

16.

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.

11

Section XI

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
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
following distance must be increased.

be

minimum
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
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.

easily

12

16.

Grades must be ascended or descended slowly.

Section XI

Traveling (Continued)

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

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
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.

load.

edges of

13

Section XII

Stacking and Unstacking

Part

1.

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
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
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
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
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.

lower

pallets.

in a

be

Section XIII

Bridge Plates and Other Vehicle Boarding Devices

14

Part

1.

Bridgeplates, 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 XIV Loading and Unloading Highway Truck Trailers

15

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
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
in the position closest the rear of the trailer. A A frame can be used as a
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.

being

secured
support

Section XV
Part

1.

Parking
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.

16

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
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,
be blocked and approved by your supervisor.

vehicle

wheels must
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
valve at the cylinder and then run the engine until the fuel in the line is

supply
exhausted.

Section XVI

Trucks Powered by Gasoline or Diesel Oil

Part

1.

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.

17

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 XVII

Part

LP Gas Fueled Trucks

1.

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
must be closed before the coupling is opened, and the valve on the
must remain closed until the fuel line is securely reconnected.

cylinder
full cylinder

18

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
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.

to run

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 XVIII

Part

Electrical Powered Lift - Trucks

1.

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
trucks, and for safe dispersal of fumes from gassing batteries.

damage by
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.

19

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 XIX

Part

Liquid Propane

1.

Propane, Butane or mixtures of the two are the principle components of LPGas. They are obtained in great quantity from oil and gas wells and from
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
many other materials.

natural

dissolve in
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.
20

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 :
Date :

Company :
/

X = UNSAFE ACTION

O = INCORRECT ACTION

C = CORRECT ACTION

LOAD PICK UP

STACKING LOAD

Fork Entry
Pallet Movement
Other

Placing Load
Mast Tilt
Fork Exit
Other

LOAD TRANSPORT

STACKED LOAD PICK UP

Mast Tilt
Load Height
Speed
Horn
Other

Park Brake
Mast Tilt
Fork Entry
Other
.
21

.
.
.

.
.
.
.

SPOT PLACEMENT

VEHICLE SHUT DOWN

Front Line
Back Line
Other

Mast Tilt / Forks Down

Transmission Neutral
Park Brake
Power / Engine Off

.
.
.
.

COMMENTS :

.
(

) Operator Qualified To Operate Forklift Truck

) Operator Requires Additional Training

On (Date)

(Social Security Number)

Forklift Truck.
(Forklift Type)
(Load Capacity)

(Print Name)
-

.
Was Evaluated For Safe Operation Of A Powered
(Mode Of Power)

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)

22