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PURPOSE / OBJECTIVE
To make certain that all Contractor Forklift Operators will be reminded / refreshed on their responsibility as well as on forklift safe operation practices to minimize incidents while operating forklift Trucks.
MAJOR COMPONENTS OF FORKLIFT
Each forklift Operator shall be re-trained and re-qualified every three years. Beside having a valid government heavy equipment license. All forklift Trucks shall be equipped with a dry chemical fire extinguisher.REQUIREMENTS All new Forklifts trucks shall meet the design and construction requirements of Part ll. training qualification program shall be in place for forklift operators. No alterations or modifications that affect the capacity or safe operation of a forklift shall be made without prior written approval of the manufacturer. Shall have a functional horn. Spinner knobs on the steering wheels are not recommended. ANSI B56.1-1969 or equivalent. safety blinking/flashing lights and back-up alarm. 4 .
who satisfactorily completes the qualifications as outlined above shall be issued a certification card as evidence of being a qualified Forklift Operator.REQUIREMENTS The following requirements shall be met to become ³Qualified Forklift Operator´: ± ± ± ± Be medically fit Posses a valid Saudi driving license Pass the written test Perform the demonstrated capability requirement satisfactory Forklift operators. 5 .
Unauthorized passengers shall not be permitted to ride on powered industrial trucks. load engaging means shall be lowered. Using Forklift for lifting personnel is prohibited. whenever he steps out from the Forklift. ear plugs in the Forklift Cabin. control shall be neutralized. He shall use PPE as applicable.REQUIREMENTS Seat belt shall be worn while driving. When a Forklift is left unattended. 6 . Avoid working near the Forklift. and brake set. A forklift is considered unattended when the operator is 7. power shall be shut off.5 m (25 feet) or more away from the vehicle which remains in his view. Forklift operators shall keep safety hat. Duckboard or bridge plates shall be properly secured before they are driven over. Stunt driving and horseplay shall not be permitted. Wheels shall be blocked if the forklift is parked on an incline. glasses. at least in 2-meter distance.
REQUIREMENTS An overhead guard shall be used as protection against falling objects. Copies of the manufacturer¶s operating instructions for each type of forklift truck shall be readily available for review by operators and supervisory personnel. Report all accidents and nearmisses to your supervisor. Forklift trucks that are defective. 7 . A maintenance log shall be kept on each forklift truck to determine when required maintenance is due. and taken out of service until restored to safe operating condition. in need of repair shall be tagged ³Danger ± do Not Operate´ tag. Additional counter weighting of fork trucks shall not be allowed unless approved by the manufacturer. Maintenance and repair shall be performed only by qualified personnel. Refueling and battery changing operations shall be performed only in designated areas of the plant.
8 . use only the hook provided for this purpose.Operating Requirements Never operate defective forklift Never operate a forklift unless qualified and authorized Never permit anyone to ride on any party of a forklift Never overload a forklift Pushing one forklift with another is prohibited. Never remove radiator cap when forklift is overheated. Horseplay is not permitted When it is necessary to use the forklift for towing.
AUTHORIZED & TRAINED OPERATOR ONLY 9 .
10 .NO RIDERS A lift Truck is built for only one person ± the operator. A lift truck is not designed to lift people.
Driving Requirements Obey all traffic regulations Never drive with wet or greasy hands Always drive at a safe speed. Give proper signals for turning. and sound horn. Slow down when making turns. slowing or stopping 11 . Make sure they see you. Always give warning when approaching anyone from the rear. Drive slowly over rough roads Approach blind corners slowly. Keep feet and hands inside forklift. kept to the right. The horn is to be used only as a warning to others and not to demand the right-of-way. Avoid driving over objects on floors or roadways it may shift or topple the load.
Drive in reverse when carrying load down ramp or incline. always look in the direction of travel.Driving Requirements (cont.) When driving without load. Approach floor openings. keep forks no higher than 15 cm(6 inches) above floor or ground. Do not race another forklift. For better vision. When following another forklift. look and sound horn hen leaving or entering buildings. Before entering an elevator. Stop. 12 . keep a safe distance behind. be sure that its capacity is sufficient for the weight of the truck plus the load. Do not travel abreast (side by side) of another forklift. Never cut corners around stacks of materials or stationary objects. elevator wells and loading platforms slowly. Avoid turning around in crowded aisles. After entering elevator. Keep away from the edges or platforms or ramps Test brakes before driving down ramps or slopes. lock brakes and turn off power of forklift.. Drive up ramps when carrying a load. drive backward with bulky loads.
travel up or down a slope with forks arms facing the slope. Do not attempt to turn around on a slope or travel across a ramp of incline. 13 .Drive up ramps when carrying a load When loaded.
14 . A lift truck is less stable when the forks are elevated. The combination of speed and the sharpness of a turn can cause a tipover.TRAVEL SLOWLY WHEN TURNING Lift trucks can tipover even at very slow speeds. with or without load.
TRAVEL SLOWLY WHEN TURNING Do not turn on an incline. To reduce the possibility of a tipover. a lift truck must not be driven across an incline 15 .
16 .TRAVEL SLOWLY WHEN TURNING Failure to observe the tail swing area when making a turn can injure or kill someone.
This action permits the lift truck to enter the narrow aisle going straight ahead.TRAVEL SLOWLY WHEN TURNING When turning the lift truck from a wide aisle into a narrow aisle. 17 . start the turn as close to the opposite stock pile as tail swing will permit.
LOAD HANDLING. This rating represents the maximum load that can be lifted. 18 . GENERAL Handle only loads within the rated capacity as shown in the nameplate.
19 . GENERAL Do not handle a load if any loose part of it is above the load backrest or any part of the load is likely to fall. A load can have unstable items that can easily shift and fall on someone. Handle only stable loads.LOAD HANDLING.
GENERAL Position each fork the same distance from the center of the carriage. If the weight of the load is not centered between the forks. Center the weight of the load between the forks.LOAD HANDLING. the load can fall from the forks when you turn a corner or hit a bump. 20 .
Driving without Load Always travel with forks lowered within 150 mm of the ground. 21 .
Stop vehicle with brakes before changing direction of travel. Lower forks fully leaving the operator¶s position.Stops and Starts Requirements Avoid sudden stops and starts. These may cause skidding or toppling of the road Travel slowly on slippery surfaces Never use reverse as a brake. 22 . Always look to see that the way is clear before starting ahead or backwards.
chalwyn fitted) or authorized by a vehicle movement permit with proper gas testing. unless forklift is explosion proof (safety equipment like pyroban. 23 .Gaseous Areas Requirements Never operate a forklift in classified area.
If necessary. 24 . Place material securely on the pallet at all times. use pallets. Never carry a load so high that you cannot see ahead. Avoid carrying loose material on forks.Carrying Load Never load a forklift beyond its rated capacity Always carry loads at least 15 cm (6 inches) above floor or ground. Place red flag on material that protrudes from either side. Carry the weight close in on the forks Never allow anyone to stand under elevated loads. operate truck in reverse.
Determine the center of gravity 25 .Before Lifting Determine the weight of the load.
Fork Lift Capacity The load data on the fork lift truck will indicate the maximum load at a specified distance for example: 500 KG at 600mm. the load capacity is decreased. 26 . By increasing the load center distance.
Forks equally spaced. perfect and stable 27 . load will compress and be damaged. load will fall off apart. Forks too far apart.Supporting the Load Forks too close together.
28 .Inserting of Forks It is essential to keep the forks horizontal when inserting the forks into an empty or loaded pallet.
damaged will occur. the forks are horizontal.Inserting of Forks If the forks do not enter and exit the pallet freely. With the masts vertical. 29 .
Inserting of Forks It is not always possible to fully insert the forks under a load when off loading a truck or destacking. Lower the load slowly and carefully to the ground. Insert the forks as far as possible Ensure the load is safe before off loading. Fully insert the forks to the backrest Raise the forks. tilt back and proceed as usual. 30 .
31 .Carrying Load Make yourself aware of the capacity of the forklift.
32 .Carrying Load The mass of the counterweight acts as a counterweight so that a load can be lifted without the fork tipping forward.
Carrying Load The fork truck will tip forward if the load is too heavy. or if the load is incorrectly placed on the forks. or braked harshly. 33 .
raising the forks only on approaching incline or loading ramp.Drive Carefully Be aware that bumpy floor. Always travel with the load 150mm or 6inches from the ground. 34 . pot holes and ramps can cause loads to be jolted and dislodged.
Pick up the load under the center of its weight to avoid tipping the truck over or shifting the load. Never pick up a load until forks are properly placed beneath the pallet. A sudden stop will cause the machine to tilt forward and may tip the machine or throw the operator. 35 . Be sure to return tilt to vertical before lowering or picking up a load.Using Lifting Device Before lifting be sure that loads are stable and properly balanced. Tilt the load against the backrest before moving the truck. Lower load slowly.
TRVELLING Load should be properly secured before transporting.LOAD HANDLING. 36 .
37 . keep load the carriage and the mast fully BACKWARD. TRAVELLING When traveling with the load lowered.LOAD HANDLING. Travel with the lift mechanism raised only enough to clear the earth or obstacles.
a lock out helper can be required.LOAD HANDLING. If visibility is obstructed. but always keep a proper lockout in the direction of travel. TRAVELLING For better visibility with large loads. 38 . travel with the load trailing.
39 . TRAVELLING Avoid bumps holes. slow down. slick spots and loose materials that may cause the lift to swerve or tip.LOAD HANDLING. If unavoidable.
LOAD HANDLING. operate the lift truck at a speed that will permit to be brought to stop in a safe manner 40 . TRVELLING Under all travel conditions.
TRVELLING Maintain a safe distance from the edge of docks. 41 . platforms and other similar working surfaces.LOAD HANDLING. do not jump off! Hold firmly to steering wheel. Watch ³tail swing´. ramps. and lean forward and away from the point of impact. brace your feet. If the lift truck fall off the dock.
When placing or when picking up pallets. Observe clearance rules at aisles. etc. Never obstruct fire fighting equipment. Warn other employees to stand clear when stacking or removing material. Avoid stacking material in roadways or aisles. pipelines. sprinkler heads. Never attempt to reach through uprights. Be sure there is sufficient head room when raising loads. 42 . lights and other obstructions.Stacking and Removing Material Never overload floors when stacking material. Watch for beams. Keep emergency doors clear of obstruction. be sure not to unbalanced the pallets.
43 . Lift and tilt back to ensure maximum stability.Stacking with Counterbalanced Fully insert forks to the backrest.
Apply the parking brake and select neutral.Stacking with Counterbalanced Approach the stack as squarely as possible. Slow down and stop at the face of the stack. Reduce the backward tilt to an amount that keeps the load stable. 44 .
Raise the load to the desired height.Stacking with Counterbalanced Look up and check for obstructions. 45 .
Take care not to dislodge loads in adjacent stacks. Apply parking brake and select neutral.Stacking with Counterbalanced Move slowly forward. Stop when the load is over the stack. Reduce the back tilt until the load is horizontal and level. Slowly and smoothly lower the load onto the stack 46 .
It is much easier to off load in a neat and tidy way if the pallet is initially positioned squarely on the forks.Stacking with Counterbalanced When the load is securely stacked. withdraw by reversing the fork truck. 47 . Keep a continuous lookout all around the moving fork truck. Take care that the forks do not bind on the pallet during withdrawal. After checking that the way is clear. lower the fork arms until free of the pallet.
Check all around that the way is clear before moving off.Stacking with Counterbalanced When clear of the stack. 48 . apply the parking brake and select neutral. Lower the fork arms to just above the ground (150mm) and apply a slight back tilt.
Stacking with Counterbalanced Safe traveling with the forks just off the ground (150mm) with slight back tilt. 49 . Sound the horn on blind corners. Watch out for pedestrian and always give them the right of way. Look out for other traffic. Do not speed or turn corners abruptly.
DEDE-STACKING WITH COUNTERBALANCED Stop at the face of the stack and apply the parking brake Bring the mast to a vertical position. Adjust the fork spread to suit the width of the load on the pallet. Ensure the weight of the load is within the capacity of the lift truck 50 .
51 .DEDE-STACKING WITH COUNTERBALANCED Look upwards Raise the fork arms to a position permitting clear entry into the pallet.
Apply the parking. 52 .DEDE-STACKING WITH COUNTERBALANCED Fully insert the fork arm by slowly driving forward until the heels of the forks gently touch the pallet base or load.
Observe that the load is stable.DEDE-STACKING WITH COUNTERBALANCED Lift the load clear of the stack and carefully apply a backward tilt. 53 .
DEDE-STACKING WITH COUNTERBALANCED Look around to check that the way is clear. Apply the parking brake. Move slowly backwards until the load and fork arms are clear of the face of the stack. 54 . Take care not to dislodge loads in adjacent stacks.
Look out for other traffic. Apply further backward tilt to ensure maximum load stability. Watch out for pedestrians and always give them the right of way. Do not speed or turn corners abruptly. 55 .DEDE-STACKING WITH COUNTERBALANCED Lower the load carefully and smoothly to the correct traveling position with the forks just off the ground (150mm). Check that the way is clear. Sound the horn on blind corners.
Do not wear dark glasses in dark areas when loading and unloading in varying intensities of light. Before driving into trailers. and loading or dock plates are secured. be sure their brakes are set. 56 . Always have both doors open before operating a forklift inside containers. trailers. chocks are in place.Loading and Unloading Requirements Before entering highway truck or trailers. Enter and leave containers and trucks slowly. Never use duck boards or loading plates that are damaged. walk in car and inspect floor.
Load Handling. Lowering and Tilting Do not tilt or hit anything that can fall on the operator or a bystander. Avoid hitting objects such as stacked material that could become dislodged and fall. Lifting. 57 .
Load Handling, Lifting, Lowering and Tilting
The lift truck can tip over forward when the load is raised. Forward tipping is even more likely hen tilting forward, braking when traveling forward or accelerating in reverse. If the lift truck tips over, do not jump off! Hold firmly to steering when, brace your feet and lean away from point of impact.
Load Handling, Lifting, Lowering and Tilting
Avoid fast starts. Sudden movement can cause the lift truck to tip.
Never step off a forklift until it has come to stop Never leave a forklift unattended with motor running
± Lower the load ± Turn off the engine ± Set the hand brake
Park only in designated places. If it is necessary to park on an incline set the brakes and choke the drive wheels
61 .PARKING SAFELY When parking it is essential to lay the forks flat on the ground.
When lifting batteries with chain slings or metal grips. 62 . Keep all electrically ³live´ parts protected.Electric Driven Trucks Requirements Never use reverse controls for brakes Never operate with weak batteries Cut off power and set brakes before starting to change battery. Hydrogen gas may be present which may cause an explosion or fire. avoid short circuits by preventing metal parts from touching the contact terminals. Keep open flames away from battery. Smoking is prohibited when batteries are being charged.
Combustion Engine Powered Forklift The procedure to safely refuel: Never refuel a forklift inside a building. This will prevent static sparks. Fuel tanks shall not be filled while the engine is running. 63 . Store and carry fuel in safety cans where pump is not used. Make sure hose nozzle makes contact with tank while filling. Avoid overfilling the fuel tank.
± Finish removing hose from cylinder. safety glasses on. 64 . Wear long sleeves. rubber gloves. empty and damaged cylinder at the designated location and tag-out the damaged cylinders.LPG Powered Fork forklift Shut off engine. ± Unclamp cylinder from forklift and place in empty cylinder storage rack with valve end toward the back. Crack hose fitting to tank to bleed off pressure. ± Always use steel pallets for transferring the empty and filled cylinders and chain it properly. safety shoes when changing cylinder. safety glasses. set the brakes and connect grounding clamp LPG Cylinder Removal: ± Block valve on cylinder ± With gloves. ± Keep separately the filled.
) Installing New LPG Cylinder: ± ± ± ± Check that block valve is closed. Check cylinder fitting and that ³O´ ring is in place. Verify that safety valve is not leaking (cold burn) Place cylinder in bracket on forklift with safety pin through cylinder hole.LPG Powered Fork forklift (cont. ± Install hose to cylinder (hand tight is good enough) and make sure that the hose is not binding. ± Clamp cylinder to fork truck ± Open valve on cylinder and observe for leaks. 65 ..
etc.Forklifts in Classified Area Forklifts that can be operated in classified area without a proper permit shall be fitted with safety equipment to reduce the risk of accidental ignition of surrounding gas. vapor or dust concentrations by the engine. Example are pyroban.the safety equipment normally fitted are: ± ± ± ± ± Engine air intake closure valve Automatic fuel shutdown valves Exhaust spark arrestors Flame-proof alternators Engine monitoring and automatic shutdown valves 66 . chalwyn.
DAILY REPORT INSPECTION FORM Equipment No. ________________ Operators Name: __________________ VISUAL CHECK Adequate fuel Oil Radiator Coolant Tire condition Head Lights Warning lights Hour Meter & Gauges Battery plug connection (electric) Obvious damaged and leaks Operational check/functional test Horn (loudness) Reverse Warning Signal Steering Hydraulic Oil Level Tilt control Side shift Forward / Reverse Service Brakes Parking brakes 67 REMARKS Date: __________________ Time: _________________ Signature: ______________ CORRECTION TAKEN OR PLANED .