FORKLIFT TRAINING MANUAL - Betty Mills

1 FORKLIFT TRAINING MANUAL 2 TABLE OF CONTENTS Disclaimer .. 5 How to Use the FORKLIFT Operator MANUAL .. 6 CHAPTER I .. 7 PLANNING THE FORKLIFT OPERATOR COURSE .. 7 I. HOW TO ESTABLISH OBJECTIVES .. 7 II. HOW TO DO RESEARCH ABOUT OPERATOR .. 8 III. HOW TO DEVELOP A BUDGET .. 11 IV. HOW TO SCHEDULE SESSIONS .. 11 V. HOW TO CHOOSE AND SET UP TRAINING SITES .. 11 VI. HOW TO OUTLINE THE TRAINING COURSE .. 12 CHAPTER II .. 13 ASSIGNING RESPONSIBILITIES .. 13 I. SUPERVISOR RESPONSIBILITIES .. 13 II. FORKLIFT OPERATOR RESPONSIBILITIES .. 14 III.

2 TRAINING RESPONSIBILITIES .. 15 CHAPTER III .. 16 PREVENTING FORKLIFT ACCIDENTS .. 16 I. SIX COMMON CAUSES OF ACCIDENTS .. 16 II. SPEEDING: GOING NOWHERE FAST .. 16 III. THE COST OF ACCIDENTS .. 17 IV. HOW TO REDUCE THE RATE OF ACCIDENTS .. 18 V. MOST COMMON POWER TRUCK ACCIDENTS .. 18 VI. A LOOK AT WALKIE ELECTRICS .. 19 CHAPTER IV .. 21 SAFETY TRAINING PROGRAM .. 21 I. TRAINING EMPLOYEES .. 21 II. LICENSING .. 23 III. CERTIFICATION .. 24 IV. DOCUMENTATION .. 24 V. INTRODUCTION TO LESSONS .. 25 VI. TRAINING COURSE OVERVIEW.

3 26 3 CHAPTER V .. 28 I. HELPFUL HINTS .. 28 II. INCENTIVE PROGRAM OPERATOR POOL .. 28 III. INCENTIVE PROGRAM TEAM EFFORT .. 29 IV. INCENTIVE PROGRAM QUARTERLY REVIEW .. 30 V. CASE STUDIES .. 31 CHAPTER VI .. 32 I. THE PERFORMANCE TEST .. 32 II. OBSTACLE COURSES .. 32 III. REVIEW .. 35 FORKLIFT - LESSON # 1 .. 36 PRINCIPLES OF FORKLIFT EQUIPMENT .. 36 I. LEVER PRINCIPLE .. 36 II. FULCRUM PRINCIPLE .. 36 III. DATA PLATE .. 37 IV. LOAD CENTERS .. 37 V. CENTER OF GRAVITY .. 38 VI. MOMENTUM .. 38 VII. STABILITY TRIANGLE.

4 39 VIII. HYDRAULICS .. 39 IX. REVIEW .. 40 FORKLIFT - LESSON # 2 .. 40 SAFE OPERATIONS AND OSHA REQUIREMENTS .. 40 I. OSHA REQUIREMENTS FOR FORKLIFT OPERATIONS .. 40 II. SAFE OPERATING RULES .. 41 III. EMPLOYEE FORKLIFT OPERATOR TRAINING QUESTIONS .. 44 FORKLIFT - LESSON # 3 .. 45 MATERIAL HANDLING .. 45 I. MATERIAL HANDLING CHECKLIST .. 46 II. MATERIAL HANDLING EQUIPMENT .. 47 4 FORKLIFT - LESSON # 4 .. 48 OPERATOR MAINTENANCE .. 48 I. CRITICAL MAINTENANCE ITEMS .. 48 II. DAILY INSPECTION CHECKLIST .. 50 III. INSPECTION AT DRIVING OFF.

5 51 IV. OPERATOR MAINTENANCE (ELECTRICS) .. 52 FORKLIFT - LESSON # 5 .. 54 FIRE PREVENTION .. 54 I. TWO GENERAL RULES .. 54 II. EXTINGUISHERS .. 54 III. SPRINKLER SYSTEMS .. 55 IV. PREVENTION .. 56 V. TERMINOLOGY .. 57 VI. REVIEW .. 58 NEW FORKLIFT RULES ADOPTED IN 1998 .. 65 ADDITONAL INFORMATION RELATING TO FORKLIFTS AND SITE-SPECIFIC TRAINING .. 74 OSHA REGULATION INTERPRETATIONS RELATING TO FORKLIFT EQUIPMENT ARE INTERPRETATIONS FROM LETTERS WRITTEN TO OSHA ABOUT A SPECIFIC REQUIREMENT .. 82 FORKLIFT OPERATOR EVALUATIONS .. 83 PROPANE SAFETY (IF YOU USE PROPANE, TRAINING IS REQUIRED).

6 85 BATTERY CHARGING SAFETY .. 87 RIDER PALLET JACK (required if you use pallet jacks) .. 89 WOOD PALLET SAFETY .. 92 5 DISCLAIMER Information provided in this written material should not be considered as all encompassing, or suitable for all situations, conditions or environments. Each organization is responsible for implementing their own safety / injury / illness prevention program and should consult with their legal, medical or other advisors as to the suitability of using the information in this MANUAL . Application of this information does not guarantee you will be successful in your safety efforts, or that the information will meet all State or Federal OSHA standards or requirements.

7 (State or Federal OSHA Consultants will not guarantee their services will meet all applicable State or Federal OSHA regulations, or by implementing their recommendations that your company will be in OSHA compliance). At the time this information was provided, it was believed to be from reliable sources and current with applicable local, state or federal safety standards, however, the producers of the program assume no liability arising from the use of, or reliance on the information provided. Always seek the advice of your legal, medical or other advisors as necessary before using this information in your company's safety efforts.

8 COPYRIGHT 1998 ALL RIGHTS RESERVED DIGITAL-2000, INC. 12783 Capricorn Suite 100 Stafford, TX 77477 800-334-1523 281-313-0303 281-313-0304 FAX For those organizations who have purchased this program, you may freely copy the information for use in your company's safety efforts; however, all the material is copyrighted and may not be used for resale, rental, lease or other similar uses to gain a profit. During the course of this MANUAL , feel free to make changes or delete any information that may not be applicable to your operations. The company policy statement herein, may or may not be suitable for your company's policy statement, so you may want to change the wording of your policy statement, as well as other parts of the program.

9 VIDEOS AVAILABLE FOR USE IN TRAINING 1001G FORKLIFT OPERATOR SAFETY English and Spanish 1002G FORKLIFT INSTRUCTOR TRAINING English and Spanish 1003G FORKLIFTS/PEDESTRIAN SAFETY English only 1004G YOU RE THE ONE (humorous) English only 1005G SUPERVISORS AND FORKLIFTS (humorous) English only 1006G FORKLIFT MECHANIC SAFETY English only 1007G SAFETY OF PEOPLE/EQUIPMENT WAREHOUSE English only 1008G POWERED PALLET JACK (WALKIE STACKERS) English and Spanish 1009G SAFE HANDLING OF WOODEN PALLETS. English and Spanish 1010G BATTERY CHARGING SAFETY English and Spanish 1011G PROPANE SAFETY.

10 English and Spanish 1012G ORDER STACKER SAFETY English and Spanish 1013G ELECTRIC PALLET JACK (RIDER & MANUAL ) English and Spanish 1016G FORKLIFT 2000 the new rules English and Spanish 1017G SITE SPECIFIC TRAINING MODULES English and Spanish 7035A FORKING AROUND-WHAT S WRONG WITH THIS PICTURE English only 6 FORKLIFT OPERATOR TRAINING MANUAL A company that is able to stay in business and prosper isn't always the one that sells the most goods or services. It is the one that is able to do the best job at controlling costs. No company can lose a little on each sale, but make a profit with volume.