Copyright © MMIV by Mangan Communications, Inc. • www.mancomm.com

Chapter One Video 1 Training and Basic Principles 1

Chapter Two Video 2 Operation 11

Chapter Three Video 3 Loading 17

Chapter Four Video 4 Pre-Operation Inspection and Refueling/Recharging 23

Table of Contents

DisclaimerAlthough the author and publisher of this book have made every effort to ensure the accuracy andtimeliness of the information contained herein, the author and publisher assume no liability withrespect to loss or damage caused by or alleged to be caused by reliance on any information con-tained herein and disclaim any and all warranties, expressed or implied.

ii

IntroductionWelcome! This video and workbook program contains the resources to help your companycertify forklift operators.Great care has been taken to make this program easy to use and complete for your needs.This training course is intended to provide guidelines and knowledge toward performance inforklift operation that will help reduce the number of accidents, injuries, and deaths relatedto improper forklift operation.

• Forklift safety training must be providedto operators BEFORE they operate anyforklift.

• Refresher training and skills appraisalmust be given to forklift operatorswhenever new equipment is acquired,current equipment is modified, theworkplace operating environmentchanges, an operator has an accidentor near miss, or has been observed tooperate the forklift in an unsafe manner,or when an evaluation reveals that theoperator has not been operating thetruck safely.

FORKLIFT FACTS:

Please note that in this training program, the terms forklift, fork truck, lift truck, truck,and powered industrial truck will be used interchangeably to refer to all types of pow-ered industrial trucks.

FORKLIFT FACTS:

Every forklift operator must receive training and authorization from his/her companyprior to operating any type of forklift.

How to Use These Materials

1. You should view the four (4) videos. Video 1: Training and Basic PrinciplesVideo 2: OperationVideo 3: LoadingVideo 4: Pre-Operation Inspection and Refueling/Recharging

They can be viewed either one-on-one or in a group setting, such as a safety or training meeting.Each video runs approximately 10 minutes.

2. You should review the operator workbook and complete the review questions at the end ofeach section.

3. You may view the videos as many times as you wish.4. Your trainer will walk you through the work environment in which you will be authorized to oper-

ate, pointing out specific operating conditions, obstacles, pedestrian traffic patterns, and haz-ards, as well as company-specific requirements for safe forklift operation.

5. Your trainer will review specific requirements for the powered industrial truck(s) you willbecome authorized to operate.

6. You will then run through the practical operating skills with your trainer and prepare for the per-formance evaluation using the maneuvering practice drills.

7. You will receive a completion certificate and a wallet card after you perform these steps successfully.

12 Chapter Two - Video 2

29 Accident Prevention Rules for Safe Forklift Operation When driving a powered industrial truck, there are many precautions to follow in order tomaintain a safe workplace:

1. Do not drive up to anyone standing infront of a fixed object. Examples of fixedobjects include cargo, pallets, benches,and walls.

2. Never let anyone stand or pass underthe elevated portion of any truck,whether it is loaded or unloaded. Neverwalk over or under the forks; alwayswalk around them.

3. Do not let unauthorized passengers rideon your truck. You should be the onlyoccupant unless it is equipped with a safeplace for authorized co-workers to ride.

4. Keep your arms and legs inside the running lines of your truck and always wear yourseat belt. Never stick any part of your body between the uprights of the mast.

5. If you leave your lift truck unattended, you will be more than 25 feet away, or if thetruck will be out of your view, the load engaging means (such as forks or attach-ments) must be lowered, the parking brakes set, the controls neutralized, and thepower shut off. If the truck is parked on an incline, the wheels must be blocked. If youare getting off the forklift but will be in view and within 25 feet of the lift truck, the forksor attachments must be fully lowered, the controls neutralized, and the brakes set.

6. Maintain a safe distance between the truck and the edge of any loading dock, ramp,platform, bridgeplate, or other vertical drop.

7. Do not use your lift truck to open or close freight doors. 8. Before entering a semi trailer, be sure that it is stabilized. Make sure wheel chocks or

dock locks are in use. If the trailer is attached to the cab, the parking brake must beset. If the trailer is not attached to the cab, a trailer stabilizing jack may be used to pre-vent the trailer from tipping when heavy loads are moved into the front of the trailer.

9. Before entering a railcar, make sure it is fixed in position with wheel chocks or othersafety devices. Never enter a trailer or railcar with people inside it.

10. Check the floor for broken or missing planks before entering a trailer or railcar. Fork-lifts are very heavy, and a cracked or weakened floor might give way under theweight of the lift truck.

11. Make sure the mast, load, and load backrest have sufficient headroom under over-head installations, lights, pipes, sprinkler systems, etc. These installations could bedamaged by a collision with the forklift, and the forklift operator could be electrocuted,burned, or poisoned by gases, toxic liquids, or whatever else is in the installations.

12. The forklift must have an overhead guard to protect the operator from falling objects.A load backrest extension shall be used whenever necessary to minimize thechance of the load (or part of it) from falling rearward.

13Operation

13. In hazardous locations, only use powered industrial trucks that are approved for thoselocations.

14. Keep fire aisles and access to stairways clear, and never block exits or fire equipment.15. Observe all traffic regulations and signs. Always follow your company’s policy on

pedestrian traffic.16. Keep at least three truck lengths be-

tween you and the truck in front ofyou. Keep your lift truck under controlat all times. Yield the right of way toambulances, fire trucks, and othervehicles in emergency situations.

17. Do not pass another truck traveling inthe same direction if you areapproaching a blind spot, an intersec-tion, or another dangerous location.

18. Slow down and sound your horn whenapproaching an aisle, corner, or inter-section. This warning applies to any area where vision is obstructed.

19. If a load blocks your forward view,drive in reverse with your load trailing,and always look in the direction oftravel.

20. If at all possible, cross railroad tracksdiagonally, and never park closer than8 feet from the center of a railroadtrack.

21. Drive up and down grades slowly, andnever travel diagonally across anincline. When ascending or descend-ing a grade greater than 10%, alwaysdrive with your load facing uphill. Thisusually means backing down a rampwhen unloading a freight container.Many forklift manufacturers suggestthat you drive your unloaded truckwith the forks facing downhill. On allgrades, the load and forks should beraised just high enough to clear theroad surface, and the load should betilted back to cradle the load and helpkeep it from slipping off the forks incase of a sudden stop.

FORKLIFT FACTS:

In a situation where you need to go forward and a load is blocking your view — suchas going up a ramp that requires you to drive forward — you will need a spotter tohelp guide you.