Operator's manual

of FORKLIFT
OPERATOR'S MANUAL
YOU WILL BE TRAINED AND AUTHORIZED
TO OPERATE FORKLIFT

You can prevent accidents

READ, UNDERSTAND AND APPLY THE

INSTRUCTIONS IN THIS MANUAL

Learn all about the equipment

mobile that you operate.

2
OPERATOR'S MANUAL.............................................2
/YO CAUTION.................................................15
/! COMBUSTION GASES...................................15
CAUTION RISK OF FIRE.................................16
The Lever Theory Applied to the Forklift............17
The Lever Theory Applied to the Forklift............18
The Lever Theory Applied to the Forklift............19
The Lever Theory Applied to the Forklift............20
Capacity (Weight and load center).......................21
2. INSPECTION AND TESTING OF THE UNIT.22
Minor preventive maintenance for Forklift
operators...............................................................26
Minor preventive maintenance for Forklift
operators...............................................................26
Additional remarks...............................................31
3. General Safety Rules Things to do and what not to
do..............................................................................33

3
 General Safety Rules Pedestrians and cyclists........35
General Safety Rules Operator protection...............36
General Safety Rules Points with danger of
entrapment................................................................38
General Safety Rules Motion..................................39
General Safety Rules Surface..................................41
General Safety Rules Ability...................................42
General Safety Rules Docks and loading................43
General Safety Rules Rollovers..............................44
WARNING :.............................................................44
Off................................................................................47
4. OPERATION RISKS...........................................48
Operation Risks loose loads....................................49
Operation Risks Long and wide loads.....................50
Operation Risks Unit turn........................................51
Operation Risks Limited height..............................52
Operation Risks Fast turns and high loads..............53

4
 Operation Risks Dock Lock Program.....................54
Operation Risks Stacking at right angles................55
Operation Risks Platforms and pallets....................56
GENERAL RULES..............................................60
SAFE FORKLIFT HANDLING..........................60
SAFE LOAD HANDLING..................................62
CIRCULATION IN FACTORY..........................62
LP GAS CHARGING...........................................62
TAKE TWO..........................................................63
6. SANCTIONS....................................................65

1. GENERAL SAFETY RULES

OPERATOR'S MANUAL 2
/YO CAUTION 15
/! COMBUSTION GASES 15
CAUTION RISK OF FIRE 16
The Lever Theory Applied to the Forklift 17

5
 The Lever Theory Applied to the Forklift 18
The Lever Theory Applied to the Forklift 19
The Lever Theory Applied to the Forklift 20
Capacity (Weight and load center) 21
2. INSPECTION AND TESTING OF THE UNIT 22
Minor preventive maintenance for Forklift
operators 26
Minor preventive maintenance for Forklift
operators. 26
Additional remarks 31
3. General Safety Rules Things to do and what not to
do 33
General Safety Rules Pedestrians and cyclists 35
General Safety Rules Operator protection 36
General Safety Rules Points with danger of
entrapment 38
General Safety Rules Motion 39

6
 General Safety Rules Surface 41
General Safety Rules Ability 42
General Safety Rules Docks and loading 43
General Safety Rules Rollovers 44
WARNING : 44
Off 47
4. OPERATION RISKS 48
Operation Risks loose loads 49
Operation Risks Long and wide loads 50
Operation Risks Unit turn 51
Operation Risks Limited height 52
Operation Risks Fast turns and high loads 53
Operation Risks Dock Lock Program 54
Operation Risks Stacking at right angles 55
Operation Risks Platforms and pallets 56
GENERAL RULES 60

7
 SAFE FORKLIFT HANDLING 60
SAFE LOAD HANDLING 62
CIRCULATION IN FACTORY 62
LP GAS CHARGING 62
TAKE TWO 63
6. SANCTIONS 65
2.

8
 INTRODUCTION

FORKLIFTS are specialized equipment with unique

operating characteristics, designed to perform specific
jobs. Its function and operation is not like that of a car.
They require specific instructions and rules for their safe
operation and maintenance.
The safe operation of the FORKLIFT is of utmost
importance. importance in
DRIVERS
MONTERREY. Experience with accidents related to
FORKLIFT has shown that when accidents occur and
people are injured or die, the causes are:
• FORKLIFT OPERATOR THAT NO WAS
PROPERLY TRAINED.
• FORKLIFT WORKER WITH NO EXPERIENCE IN
OPERATION OF A FORKLIFT.
• NOT TO FOLLOW THE PROCEDURES OF
OPERATION AND SAFETY RULES.
• FAILURE TO KEEP THE FORKLIFT IN SAFE
OPERATING CONDITION.
For these reasons, CONDUCTORES MONTERREY
wants you to know the safe operation and correct
maintenance of your FORKLIFT.
This manual is intended to help you operate the unit
safely.
Examples:
• Safety inspections.
• Important general safety rules.
• The risks in the operation of FORKLIFT.
• Describes the components and special features of the
vehicle and their function.
• The correct procedures for its operation are explained.
The operator's manual is not a training manual. It is a
guide to help
trained and authorized operators to safely operate their
FORKLIFT by emphasizing and illustrating correct
procedures. But, it cannot cover all possible situations
that may result in an accident. You are responsible for
taking care of your equipment and avoiding risks in your
work area.
It is important that you know and understand the
information contained in this manual as well as know and
apply all of your company's safety rules. Make sure your
equipment is kept in safe condition. Do not operate a
damaged unit. And drive with caution and safety every
time you use your vehicle.
Remember, before you start operating a FORKLIFT,
make sure you understand all the procedures for
operating it.
It is your responsibility to take care of your image as
an operator and it is important for you and your family to

1
operate your vehicle safely and efficiently.
FORKLIFTS are built for heavy duty work, but not abuse.
They are designed to be reliable, but they are only as
safe and efficient as the operator and the people
responsible for their maintenance are. Do not make
repairs on these units unless you have received training
in FORKLIFT repair procedures and are authorized by
your immediate superior.
 Aim

The purpose of this manual is to provide a summary of

essential information regarding the safe operation of your
FORKLIFT and to familiarize you with its features and
how they operate. This manual is divided into five main
parts:

Part 1. Get to know the unit ... describes the main

operating components, systems, controls and other
features of the unit and its operation.
Part 2. Unit inspection and testing ...reviews and
illustrates the revisions to be made to the FORKLIFT.
Part 3. General Safety Rules ...reviews and illustrates
practices for the safe operation of a FORKLIFT.
Part 4. Operating Risks ... exemplifies and describes
the risks you may encounter most frequently when
operating your FORKLIFT.
Part 5. Safety Standards Summary

How to use this manual

The examples, illustrations and explanations in this

1
2
manual will help you improve your skill and knowledge as
a professional FORKLIFT operator while taking full
advantage of the capabilities and safety features of your
FORKLIFT.
The first section of this manual is dedicated to reviewing,
with illustrations and brief messages, the general safety
rules and the main operating risks that you will encounter
when operating your unit. Next, you will find a discussion
of typical operating procedures with specific instructions
on the safe and efficient operation of your vehicle.
Please take the time to read the “Get to Know Your Unit”
section. By gaining a good basic understanding of your
unit's features and how they work, you will be better
prepared to drive efficiently and safely.

We encourage you to carefully read the manual from

beginning to end. Take your time to read and understand
the information about general safety rules and operating
risks.
Familiarize yourself with the various procedures
described in this manual. For the answer to any
questions you have about the features or operation of
your unit, please contact your immediate superior.
Operate your FORKLIFT safely; It is your responsibility to
handle carefully. Drive defensively and always wear your
seat belt. Know the capacity and limitations of the forklift.

1
1. KNOW YOUR UNIT,
FORKLIFT COMPONENTS

Hand brake

Blade control 12
 1. KNOW YOUR UNIT.

/YO CAUTION
/! COMBUSTION GASES

Exhaust gases from internal combustion engines contain carbon

monoxide and other dangerous chemicals. Carbon monoxide is
a colorless, odorless poison and can cause unconsciousness or
death without warning. Prolonged exposure to exhaust gases or
chemicals in exhaust gases can cause cancer, birth defects, and
other reproductive hazards. Avoid exposure to combustion
gases.

If engines are operated in confined spaces, maintain adequate

ventilation or vent gases to the outside. Do not exceed the
allowable limits of contaminants in the air.

Follow the inspection and maintenance programs and

procedures in this manual. Do not alter the fuel supply, ignition
or exhaust systems.

1
5
 1. KNOW YOUR UNIT.
CAUTION
RISK OF FIRE

The hot engine and exhaust surfaces of forklift

internal combustion engines can present fire hazards when
operating in areas containing flammable gases, vapors, liquids,
dusts or fibers. Surface temperatures of engine and exhaust
components can exceed the ignition temperature of common
solvents, fuels, oils, paper and other organic materials (wood,
wheat, cotton, etc.). Sparks emitted from the exhaust can easily
cause these materials to ignite. The temperature in the
Engine and exhaust surfaces increase after the engine is shut
down, presenting an increased risk of fire. Check the engine
compartment immediately following handling operations in areas
containing combustible dust, fiber or paper, and remove any
foreign material.

Operate only in areas that have been approved for forklift

operation.

The Theory of the Lever Applied to the Forklift

Simplifying the basic concept of a forklift, it can be referred to the
theory of the lever where there is a support center (connection of
the front wheels with the mast axle) and weights at each end of
the arm (weight of the forklift and weight of the load).

1
6
 1. KNOW YOUR UNIT.
You can see this in the following diagram:

As long as the Weight of the Load is less than that of the forklift,
the forklift will remain stable depending on the distance from the
center of gravity of the load.
Consider the stability of the forklift including the following:
1. Load weight greater than the maximum weight of the forklift
2. By the combination of load weight and distance of c
To know these two points we must consult the
loading diagram of each forklift.
The Lever Theory Applied to the Forklift

The forklift is designed to lift and move materials. The basic

forklift has a lifting mechanism and blades in front to support the
load. The lift mechanism lifts the load so that it can be
transported and stacked.

1
7
 1. KNOW YOUR UNIT.
To understand how the forklift can take a load, you must first
know some basic things about it.

The Forklift is based on the principle of two weights balanced on

opposite sides on a pivot. This is the same principle that a
seesaw uses. For this principle to work on a forklift, the load on
the blades must be compensated by the weight of the forklift.
The location of the center of gravity of both the forklift and the
load is also a factor.
This basic principle is used to lift a load. The forklift's ability to
handle a load must be analyzed in terms of the center of gravity
and both front and side stability.
The Lever Theory Applied to the Forklift

Stability and Center of Gravity

The center of gravity of any object is the point where the object
is balanced in all directions.

Every object has a center of gravity when the forklift lifts a load
as much as the vehicle and the load has a new combined center
of gravity

1
8
 1. KNOW YOUR UNIT.

The stability of the forklift is determined by the location of its

center of gravity or a combined center of gravity if it is carrying a
load.
A forklift has moving parts and therefore its center of gravity is
mobile (dynamic). This moves back and forth as long as the
mast tilts forward or backward.

The Lever Theory Applied to the Forklift

The center of gravity, and therefore the stability of a forklift in

1
9
 1. KNOW YOUR UNIT.
operation, is affected by a number of factors such as: size,
weight and position of the load; the height to which said load is
raised; the degree of tilt forward or backward; tire pressure and
the dynamic forces that are created when the vehicle is in
motion. These dynamic forces are caused by factors such as
acceleration, braking, turning, and operating on uneven or
inclined surfaces. These factors must be considered when
moving an unladen vehicle, also because a vehicle in these
circumstances can tip over on its side more easily than a loaded
one when carrying its load with the blades down.
The Lever Theory Applied to the Forklift

Therefore, for a forklift to be stable, the center of gravity must

remain within an area within a triangle whose base is the front
axle and the vertex is the center point of the rear axle.

If the center of gravity moves forward, the forklift will tend to lean
forward; If the center of gravity moves outside the lateral lines,
the forklift will tend to tip over on its side.

2
0
 1. KNOW YOUR UNIT,
LOADING RULES
Capacity (Weight and load center)
The capacity of the forklift is shown on the capacity plate.
Capacity is listed in terms of weight and load center. Weight is
specified in kilograms or pounds. The load center is specified in
millimeters or inches. Capacity is the maximum load the forklift
can handle. This load must weigh less than the maximum weight
of a load center shown on the Capacity Plate.

The load center of a load is determined by the location of the

center of gravity. The center of load is measured from the front
of the cargo mass, or from the loading face of an annex to the
center of gravity of the cargo. It is also assumed that the location
of the center of gravity in the vertical direction is not greater than
the specified horizontal dimension.
The operator must know if a load is within the range of the
forklift's capacity before the load is handled. 20
 2. INSPECTION AND TESTING OF THE
UNIT

Daily Inspection
Before using a
FORKLIFT, it is the
operator's
responsibility to review
its conditions. and
make sure it is found
in
safe operating conditions.

The daily inspection must It must be inspected at

be in writing to be in the beginning of each
accordance with the shift whereincludes it
Standard Technique of following:
competence Labor. - Visual checks
(Evidence of performance) - Functional reviews
Check for damage or maintenance problems and report
them for repairs before you operate the
vehicle . Unusual noises or problems should
be reported immediately to the user's
supervisor or another designated person.

2
TOOL
Do not make repairs yourself. FORKLIFT mechanics are
trained professionals. They know how to make safe
repairs.

Do not operate a unit if it needs repair, if it is in an

unsafe condition remove the key and report the
condition to the supervisor. If the vehicle becomes
unsafe in any way while you are operating it, STOP
operation of the vehicle and report the problem
immediately and have it corrected.

FORKLIFTS must be inspected every eight hours or at

the beginning of each shift . This inspection should
include a check for engine, transmission, hydraulic or fuel
system oil leaks; or any damage that may have been
caused by its operation during the previous shift.

• Make sure the top guard is in good condition.

• Check the mast and lift chains.

2
• Check the fork and load backrest extension.
• Look for loose or loose bolts and hardware.
• Check the condition of tires and wheels.
• Check all controls.
• Check engine compartment conditions. Make sure all
surfaces are free of oils, lubricants, fuel, and organic dusts
or fibers.
• Operate the unit briefly to ensure that all systems are
working properly and that all instruments including lights
and horn are working.

As a support to carry out this inspection, there is a format

(Check list).

We recommend that you use this format to make a daily

record of your inspections and the condition of the forklift.

2
 WEEK OF TO THE
Points to review: 1Turns l M M1 J. V Yes D_ll OBSERVATIONS
Engine oil level day 1
late
evenin
Transmission oil level day
late
evenin
Hydraulic oil level day
late
evenin
radiator water day
late
evenin
Review indicators day
late
evenin
Blow filter and radiator day
late
evenin
Inspection and cleaning day
late
evenin
Turret, horn and lights day
late
evenin
Extinguisher day
late
evenin
g
symbology •
YEAH
x
MC NO
corrective
DAILY AREA FORKLIFT VERIFICATION REPORT: method
M.P. Preventive
method

Prepared day shift (who made the report) Prepared day shift Received day shift
(who made the report) Prepared day shift (who made the Received late shift
report) Received night shift

The points to be reviewed in the daily inspection are

those marked in the format observed, without ruling out
visual inspections and functional reviews.

When a major failure is detected, the procedure will be

followed in accordance with the provisions of this
regulation.

Minor preventive maintenance is described on the

following sheet.

2
 Minor preventive maintenance for
Forklift operators

Level review
• Engine oil. If the engine is on, turn it off and wait 3
minutes to give the oil a chance to rest and proceed to
check the level, it should mark in the upper notch of the
bayonet. If it is in the lower notch, add SAE 30 or 40 oil
(No. Art. CD07) until you reach the top notch. The purpose
of this operation is to maintain adequate lubrication of the
engine and prevent minor damage.
• Hydraulic oil. Keep the mast in the rest position with the
engine off, check the oil level, it should reach the upper
notch of the bayonet, if the level is lower, add DTE25 oil
(No. Art. CD01) until you reach the top notch.
• Transmission Oil. Keep the engine on and at normal
temperature, with the gear selector lever in neutral position
and proceed to check the transmission oil level on the
bayonet, if you lack oil, use TRANSMISOL DEXRON (No.
Art. CD02)
• Differential oil. For inspection you must use the pit.
Remove the differential plug with a 3/8” Allen wrench. The
height of the plug is the oil level. Use MP140 oil (No. Art.
CD03)
• Directional pump oil. Make sure your unit has an
independent directional pump, remove the cap and verify
that the pump reservoir is full, otherwise add
TRANSMISOL DEXRON (No. Art. CD02)

2
 Minor preventive maintenance for
Forklift operators.

Level review (2)

• Brake fluid level. Remove the cap and verify that the
brake master cylinder reservoir is full, if not, ask the
mechanical personnel to add brake fluid.
• Battery fluid level. Send it once by
week to the mechanical workshop for inspection.
• Radiator water level. Remove the radiator cap, making
sure the engine is preferably cold. Add prepared water as
antifreeze, which can be found at the auto shop. NOTE:
Under no circumstances should you attempt to open the
radiator cap with the engine hot and off.
HAVING THE ABOVE DONE, PROCEED TO GIVE A
GENERAL BLOWING TO THE UNIT, MAKING CARE THAT
THE RADIATOR IS FREE OF DUST. Make sure the radiator
has no obstructions in the honeycomb, blow it against the
flow of the fan to remove lint and dust trapped in the
honeycomb (the life of the machine depends on the cooling
of the coolant in the radiator)

When the unit requires maintenance at the Workshop, the

following form is filled out to determine the status of the unit
upon entering the automotive workshop.
Once the unit leaves the workshop, the condition of the
forklift is checked to deliver it to the operator in charge of it.

2
 CM, SA DE CV
FORKLIFT CHECKLIST FOR MAINTENANCE
NO. Operator: ___________ Signature: _____________________
Department: ____________
Shift: __________________
Date: ______/_________/ 200_ Date: _____/___________/
200_
Entry time: ___________ Departure time: _________________________

CONDITION OF FORKLIFT AND ACCESSORIES

BUT Observations
LIGHTS: □ □ ___________________________________
TURRET: □ □ __________________________________
EXTINGUISHER:□ □ __________________________________
HORN: □ □ ___________________________________
REVERSE ALARM: □ □ __________________________________
WHEELS CONDITION: □ □ ___________________________________
SCRATCHES OR HEELS □ □
IN UNITY: □ □ ___________________________________
INTERIOR BLOWING: □ □ __________________________________
RADIATOR WATER: □ □ __________________________________
OIL LEVELS
- ENGINE: □ □ ___________________________________
- HYDRAULIC: □ □ ___________________________________
- TRANSMISSION: □ □_________________________________

% FUEL IN
GAS TANK: □ □ ___________________________________

COMMENTS:

Name and signature Name and signature of

Mechanic receipt operator

2
Visual checks
First, perform a visual inspection of the unit and its major
components. Walk and look around your unit and take note of
any obvious damage that may have been caused during the
previous shift's operation.
• Check that all safety, capacity and warning signs are
posted and legible.
• Check before and after starting the engine for any signs of
external leaks: battery fluid, transmission fluid, etc.
• Check for hydraulic oil leaks and/or loose hardware.
• Make sure that the driver's upper protection, the extension
of the back of the load and any other
device of security are in its place without
damage and
securely fastened.
• Next, check all critical components that can handle or carry
the load.
• Check the mast and lift chains. Check for obvious wear
and maintenance issues such as damaged or missing parts,
leaks, loose or broken chains, bent parts, etc. Check all
accessories, chains, cables and limit switches
• Carefully inspect the load fork for cracks, breaks, bending,
twisting or wear. Make sure the fork is correctly installed and
secured in its correct position.
• Check that the wheels and tires are properly mounted, if
there are signs of wear, and if they are pneumatic tires, they
have air pressure. 28
Functional Reviews
• Test warning devices, horn, lights and safety
accessories, including fire extinguisher.
• Start the engine and make sure all controls and
systems are working properly.
• Check the operation of the hour meter.
• Apply the service and parking brakes. This brake
should block the machine's clutch and the front tires. If
this does not happen, report it to maintenance
immediately.
•Operate all hydraulic controls: lift, tilt and auxiliary
functions, throttle, directional control and steering
system.
• Check that all controls operate freely and return
correctly to neutral.
• Operate the lift and auxiliary function mechanism (if
installed).

3
WHEN THE FUNCTIONAL TESTS HAVE BEEN
COMPLETED:

- Stop the unit completely.

- Place the directional control lever in the “N” (neutral)
position.
- Apply the manual brake.
- Turn the ignition key switch to the “OFF” position.
- Lower the lift completely.

Additional remarks

1 .- Alternator warning light

This light comes on when the key is turned to the ON position

and will go off when the machine is turned on, but if it remains
on it means that the machine is not charging.
battery report it and take it immediate maintenance.

2 .- Coolant temperature.

The coolant temperature should not exceed 120ºC. Some

forklifts have protection to stop it if this temperature is
exceeded. If it heats up above this temperature, you must stop
it immediately and report it to maintenance to avoid damage to
the engine head.

3
Standard procedure for turning off the unit

When parking and leaving the unit unattended, the lift

mechanism should be left fully down, controls in neutral,
machine off, brakes set, and key removed. Use safety heels if
the unit is parked on a slope or may move.

• Do not operate a unit that has a maintenance problem or is not

in good operating condition.
• Remove the key from the ignition key switch, use the padlock
and place a Red Maintenance Tag on the unit.
• to register failure in inspections and inform you to
the
Maintenance Manager.
•Anomalies to report immediately: Lack of brakes, lack of blade
lock, play in the steering wheel, continuous loss of oil levels,
leaks, strange noises, lack of lights, lack of fire extinguisher, etc.

IF YOU DETECT ANY ANOMALIES!

If you comply with all inspections

and they are satisfactory,
the forklift can operate. 31
 3. General Safety Rules
Things to do and what not to do

Be careful at intersections
pedestrians.

Always use the Equipment

Personal Protection (PPE)
appropriate.

Any suspicion not allowed

of alcohol/drugs.

Do not block safety equipment

or emergency
(Ex. fire extinguishers, hydrants,
emergency doors, etc.).

Smoking is prohibited inside

plant

3
 General Safety Rules
Passengers NOT
The Forklift is designed for a single
person: THE FORKLIFT OPERATOR

There should never be more than one person in the

LIFT TRUCK .

Never carry personnel on the fork of a

LIFT TRUCK
3
4
 General Safety Rules
Pedestrians and cyclists

• Watch where you go, look in the direction where you are
going.
• Pedestrians and cyclists use the same paths as you.
Apply courtesy.
• Sound your horn at all intersections or blind spots.

• Park in a suitable place designed for it.

• Take care of people in your work area even if your unit

has warning or alarm lights. They may not be expecting it.

3
 General Safety Rules
Operator protection

Stay under
overhead
protection.

Be careful
especially
when maneuver
in reverse in
very places
congested.

Be careful
with the
possible
interference of
objects in the
compartment
operator.

3
 General Safety Rules
Safety with the fork

Never allow personnel to walk under the raised fork.

There is special equipment to lift people, to work at a

height USE BASKETS, PLATFORMS, ETC.
NEVER USE THE FORKLIFT.
 General Safety Rules
Points with danger of entrapment

Keep hands and feet off

the mast (vertical).

Do not carry out repair operations on the equipment.

Do not use the

mast as a
ladder.

Notify your immediate

supervisor to report failures

3
 General Safety Rules
Motion
Always carry the
loads in one
low position and
leaning back.

Separating the
hairpins 15-25cm
ground

If the load blocks

The visibility,
advance in reverse.

Using the
proper position
to maneuver and
taking older
caution.

never back
on a slope,
nor move the
steering wheel
for
change the
address.

3
 General Safety Rules
Ramps, slopes and inclines

UNLOADED - fork uphill

LOADED - the fork uphill

 General Safety Rules
Surface

Avoid these conditions or slow down...

Ice Mud
...can cause your unit to flip

Report to General Services any anomaly on floors

where you travel by forklift.

4
 General Safety Rules
Ability

Know the weight of your unit and the load. Review the
capabilities of:

Max
weight Loading Zone NOT OK
Value
Weig Weight Load
ht
Loading Zone OK Dist. c

Distance to mast

Loading Diagram of your forklift

4
 General Safety Rules
Docks and loading
Falls can be

Beware of
pedestrians.

Be
careful Check
with the safety
edges. heels.

fatal

Maintain a safe distance from the edges of docks, ramps,

platforms and other similar work surfaces. Observe your
security perimeter.

Check the surface conditions inside the trailer bed. Make

sure the floor surface will support the weight of the forklift
and the load.

Make sure the platform wheels are blocked while loading or

unloading.

4
General Safety Rules
Rollovers

WARNING :
FORKLIFTS or loading
can tilt if handled
incorrectly.

A FORKLIFT can tip if you

violates operating rules.

4
 General Safety Rules
don't jump
Your chances of surviving a rollover increase if you
wear a seat belt to prevent you from falling.

FALL WITH THE

UNIT.
DO NOT TRY
HOP!!!

Do not
remove the
grip the
seat belt.
steering
wheel
stay in Plant your
your seat feet well 44
General Safety Rules
Parking the unit

Always
Lower stop the
the fork
forklift
to the floor and
completely
lean forward.
before exiting the
forklift.

Make
Neversure
parkthe
on
motion control
a slope.
is in neutral.

4
6
General Safety Rules
Parking the unit

Off

Turn the key to the off position.

Set the handbrake.

4
7
 4. OPERATION RISKS

This section sample

risks that may cause some
associated
close to you and the
forklift could be injured
severely.
As a trader, you must
identify other risks. Notify
your supervisor so they can help you
identify and avoid these risks.
 Operation Risks
loose loads

WARNING!

Loose Loads
Never load loose material,
uneven or misaligned.

between wide loads.

load to move.
Open the fork to adjust to the load.

Check that the mounting bolts

are securely fastened.
blade spring.

4
 Operation Risks
Long and wide loads

WARNING!

With long loads or

wide you need
more space... lower the
speed and take care
distances.

Keep loads down and

watch your balance.

Remember, a load will reduce the capacity of

the forklift.
KNOW AND UNDERSTAND
LOAD CAPACITY
OF YOUR FORKLIFT.
 Operation Risks
Unit turn

WARNING!

Rear turn

When returning, make sure the back of the unit does

not twist or hit shelves, poles, etc. . .

5
 Operation Risks
Limited height

Caution above:
When gluing with a structure on top
can overturn the forklift.

Know the height of your forklift. Check the height

you need to clear.

Keep the load down and leaning back.

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 Operation Risks
Fast turns and high loads

Slow down before turning

Your unit may tip over.

If you turn around

too forced
with high load, its
unit can
turn still in
low speeds.

Move forward with the load raised only to remove or

deposit a load.

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 Operation Risks
Dock Lock Program

WARNING!
Steps with respect to the trailer dock.

Rolling Trailer
TO AVOID RISKS YOU SHOULD:
° Talk to the truck driver personally, make sure he
does not move the trailer until you are finished.
° Apply the trailer brakes.
° Use safety heels for the wheels.
° Use systems to connect the trailer to the ramp if

The impact of entering and exiting a trailer can cause

it to move.

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 Operation Risks
Stacking at right angles

WARNING!
Stacking at right angles.

SLOWLY

When stacking at right angles or moving a lifted

load to clear objects below, avoid sharp turns and
move slowly.

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 Operation Risks
Platforms and pallets

WARNING!
Damaged or unusable platforms and pallets.

Do not move or store materials on damaged

platforms or pallets. Materials can fall through them
and cause personal injury.

Make sure the platform or pallet you are using is in

good condition and does not have defective or
missing components and fasteners.

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to stow
To place a load on a pallet...
Approach slowly and align the FORKLIFT and the
load squarely with the pallet. Lift the load as your
unit approaches the pallet. Move forward slowly until
the load is almost touching the pallet. The front edge
and sides of the loading platform must be exactly
aligned with the near edge and sides of the load or
shelf above the one you are stowing.
Stand close to the pallet and lift the load higher until
you clear the top surface of the pallet.
Slowly move the load into position. Be careful not to
damage or move adjacent loads.
When the load is aligned with the pallet below, tilt the
mast to the vertical position and carefully lower the
load onto the top surface of the pallet. Lower the fork
slightly to clear or disengage the cargo bed. Tilt the
fork forward slightly if necessary. Check the exit
path, then carefully back up until the fork is clear of
the pile. Stop and lower the fork to the riding position
(6 to 8 inches above the ground), then tilt it back to
ride. -

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 Operating procedure
Stowage Loads

To move a load from a pallet...

 Operating procedure
Stowage Loads
Approach the pallet carefully with the FORKLIFT
aligned square to the load. With the mast in the
vertical position, raise the fork to the correct height to
freely engage the load bed. Adjust the fork angle as
necessary to fit squarely under the load. Slowly
approach until your arms are under the load.

NOTE - Make sure the arms do not extend beyond the

load causing damage or overturning other adjacent
loads or materials behind the load to be moved. If the
arms are longer than the load, move the tips partially
under the load without extending beyond it. Lift the
load to clear the bottom surface. Back up a few inches,
then lower the load and slowly move forward until the
front of the fork comes into contact with the load.
Lift the load from the pallet by tilting the mast back
enough to lift the load off the surface. Check the exit
path, back out slowly until you clear the stowage, stop,
and then lower the load into the traveling position
(*see note). Make sure the load is square against the
carriage or the front face of the fork. 5

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9
 5. SUMMARY SAFETY RULES
GENERAL RULES

1. The maximum speed throughout the plant will be 10

km/h, or the prudent speed in any situation for safe
driving.
2. Use Personal Protective Equipment marked as
mandatory in the work area
3. Stay alert in the face of unforeseen situations
(stains, objects, surfaces, people, cyclists)
4. Don't be distracted, be attentive
5. Use ONLY those equipment on which you have
been trained and authorized to do so.
6. Immediately report any incident with the forklift to
security and/or general services
7. Area supervisor / Maintenance, performs
inspections before starting the shift, block when
detecting any incident
8. Do not obstruct aisles, either with loads or forklifts.
SAFE FORKLIFT HANDLING
• Drive smoothly and without abruptness when
starting and stopping.

• Think about how you are going to do the job before

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0
 SUMMARY SAFETY RULES

you start, don't improvise.

• Reduce speed in curves or corners, use the horn.

• Do not change direction on ramps.

• Drive in reverse when the load does not allow

sufficient visibility.

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1
 SUMMARY SAFETY RULES

SAFE LOAD HANDLING

1. Do not add counterweight to lift excessive loads
2. Insert the forks until the load is closest to the
mast.
3. Use “forks” of appropriate length and centered.
4. Carry the load about 10 to 15 cm off the ground.
5. Check visibility before lifting loads.
6. Do not drive with lifted loads

CIRCULATION IN FACTORY
1. You are only authorized to circulate in designated
areas, never in production areas.
2. Avoid or stop in front of congested areas or areas
with high traffic of people
3. Stop at all crosswalks and yield
4. Use mirrors at intersections and areas of poor
visibility where you need
5. Use the horn at intersections to alert distracted
pedestrians where necessary.
6. Avoid passing other forklifts, it is dangerous.
7. Extreme caution with slippery floors.
LP GAS CHARGING
1. Park in the marked area, in front of the LP GAS
station.

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2
 SUMMARY SAFETY RULES
2. Turn off the motor.
3. Block the street.
4. Notify radio surveillance so they can turn on the
LP gas charging pump.
5. Open the gas tank bleed.
6. Connect the charging hose and open the valve.
7. When filling the tank, close the gas charging valve
and tank gas purge.
8. Close the tank gas bleed.
9. Open the hose bleeder, disconnect the hose and
put it in place.
10.Notify security so they can turn off the gas pump.
11. Remove street blockages.
TAKE TWO

Learn to TAKE TWO minutes of your time to think

about safety before starting any task. Remember to
review the concepts...
Talk
• Have I talked to all stakeholders about what I intend to
do and how it might affect third parties?
• Have I talked to the right people about everything that I
think could make work safer?

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 SUMMARY SAFETY RULES
Actions
• How might my actions affect my own safety?
• How could my actions affect the safety of others?
Knowledge
• Do I know the procedures, both written and unwritten?
• Am I aware of all surrounding and environmental hazards
and do I know what to do about each of them?
Equipment
• Do I have the appropriate protective equipment for this
job?
• Do I have the right tools and equipment for this
particular job and are they in good condition?

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4
 6. SANCTIONS

Failure to comply with regulations or damages

caused, will activate the Regulation of
Montacarguistas Reprimands

Name of the cautioned: No. Employee:

Department: Area:
Name of person filing report: Plant:
Regulation of Reprimands for Forklift Riders

Caused damages
Common findings It hit, it didn't Hit, require mtto. Destroyed equipment or Run over
get hurt production
Penalties
to) b) c) d)
1. Paste on racks
2. Hit curtains
3. Hit machines
4. Knock on doors
5. Hit lamps
6. Run over people
7. Rollover
8. Hit material
9. Hit building
10. Failure to comply with safety

Penalties
a) A warning report will be issued (after 3 reports in 1 year, the driver will be removed from the truck for 6 months)
and will be suspended for 2 days.
b) You will get off the forklift for 3 months and will be suspended for 2 days.
c) You will be removed from the forklift for 6 months and suspended for 2 days.
d) You will be removed from the forklift for 1 year and suspended for 2 days.

Note:
There will be analysis and investigation in any type of finding.
Involved: Gte. of Production, Production Manager, Production Supervisor, Safety and Human Resources. For the
warning in subsection a), the event year will be considered (the 3 reports in the last 12 months). This regulation will be
subject to review

Prepared: Human Resources / Production

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