Table of Contents Chapter One
Video 1
Training and Basic Principles
Chapter Two
Video 2
Operation
11
Chapter Three Video 3
Loading
17
Chapter Four
Pre-Operation Inspection and Refueling/Recharging
23
Video 4
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Disclaimer Although the author and publisher of this book have made every effort to ensure the accuracy and timeliness of the information contained herein, the author and publisher assume no liability with respect to loss or damage caused by or alleged to be caused by reliance on any information contained herein and disclaim any and all warranties, expressed or implied.
Copyright Š MMIV by Mangan Communications, Inc. • www.mancomm.com
Introduction Welcome! This video and workbook program contains the resources to help your company certify 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 in forklift operation that will help reduce the number of accidents, injuries, and deaths related to improper forklift operation. 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 powered industrial trucks.
• Forklift safety training must be provided to operators BEFORE they operate any forklift. • Refresher training and skills appraisal must be given to forklift operators whenever new equipment is acquired, current equipment is modified, the workplace operating environment changes, an operator has an accident or near miss, or has been observed to operate the forklift in an unsafe manner, or when an evaluation reveals that the operator has not been operating the truck safely. FORKLIFT FACTS: Every forklift operator must receive training and authorization from his/her company prior to operating any type of forklift.
How to Use These Materials 1. You should view the four (4) videos. Video 1: Training and Basic Principles Video 2: Operation Video 3: Loading Video 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 of each 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 operate, pointing out specific operating conditions, obstacles, pedestrian traffic patterns, and hazards, as well as company-specific requirements for safe forklift operation. 5. Your trainer will review specific requirements for the powered industrial truck(s) you will become authorized to operate. 6. You will then run through the practical operating skills with your trainer and prepare for the performance evaluation using the maneuvering practice drills. 7. You will receive a completion certificate and a wallet card after you perform these steps successfully.
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FORKLIFT FACTS: Never change tanks near any open flame or heat source. Smoking is not allowed under any circumstances.
• Check the condition of the valves and seals before hooking up a new tank. Always hand tighten the connectors first to ensure that the threads are not crossed or stripped. Next, open the valve slowly until pressure in the line is equalized. Once the hissing has stopped, a sign that the pressure has equalized, open the valve fully, and then back it off about a quarter turn. • Do not drive away if you detect the smell of liquid propane. Leaks in the system can often be detected first by smell. Frost is another indicator of leakage. Frost will usually accumulate around fittings and valves. Any leaking tank should be tagged and moved to a company-sanctioned safe area away from any potential ignition source. Remember, propane is not just a fire hazard; it is an explosion hazard. • Propane gas is heavier than air, and will accumulate near the floor. If you suspect that a tank is leaking, the smell will be stronger near the floor. • Any truck with a propane fuel leak must be immediately removed from service and not allowed to return until the defect is repaired. • Propane tanks should be stored in an open area to prevent propane gas from accumulating.
Gasoline or Diesel Fuel Here are some guidelines for operators of gasoline or diesel fueled forklifts. • Wear proper protective equipment, including safety glasses with side shields, coveralls, and protective rubber gloves. • Never refuel near an open flame or heat source. Do not smoke in the fueling area. • Turn off the truck before fueling. • If several types of fuel are available, make sure the tank is filled with the correct type. • Do not overfill the tank. • Check for any leaks in the fuel system. • Check for any smells that might indicate a hidden leak. • Make sure to put the fuel cap back on and clean up any spills before restarting the engine.
Changing and Charging Storage Batteries Here are some guidelines for changing and charging storage batteries with forklifts. Review these principles in preparation for safe operation and performance. • Make sure you perform this operation in a designated area with good ventilation. • Know where safety equipment and fire extinguishers are located.
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Chapter 4 - Video 4
• Know where emergency shower and eyewash stations are located. • Wear proper protective clothing and equipment. This generally includes a rubber apron, rubber gloves, and a full-face shield. • Know how to operate the conveyor, overhead hoist, or other mechanical devices used to lift out batteries. Make sure the battery is secure before lifting it out of the truck. • Properly position your truck in the battery station, set the brake, put the controls in neutral, and turn off the motor. • Open the battery compartment to prevent the buildup of heat and hydrogen gas while changing the battery in a forklift. • Never use a flame for a light. Avoid flames, sparks, and electric arcs in the charging area. Observing the no smoking rule is required. • Check non-sealed batteries for the electrolyte level before charging. Never use a flame to provide illumination. Cell plates or covers should barely be covered by the electrolyte. If they are not, add just enough electrolyte or distilled water to cover the cells or plates. Never overfill, as the electrolyte expands during charging. • When making new batches of the electrolyte, pour concentrated acid into water; never pour water into concentrated acid. • Neutralize any spills of the electrolyte immediately. • Turn off the battery charger before connecting it to the battery plug and before disconnecting it from the battery plug. • Prevent tools and other metal objects from touching the terminals. Avoid any contact between the charger and any other part of the battery, as this could cause sparking. Check the cells and add more water if necessary. • Reinstalled batteries shall be properly positioned and secured in the truck. • Make sure that all vent caps are in place and functioning. Inspect for clogs. • If you find anything wrong with your forklift during refueling or recharging, report it immediately to your supervisor and have the vehicle removed from service and repaired before using.
Review Questions 1. A forklift operator should ... a. make minor repairs on the forklift himself/herself if possible. b. do a pre-operation inspection before using the forklift. c. operate a forklift with a slight leak until it is bad enough to need repair. d. turn the forklift in for repairs at the end of the shift.
Pre-Operation Inspection and Refueling/Recharging
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