SECTION 15

OPERATOR QUALIFICATIONS

1. Purpose

The intent of this procedure is to verify an operators ability to safely operate equipment before beginning actual work.

2. Before an employee is permitted to operate any type of equipment, he shall pass the attached written test and the attached Practical Operating Exam. He shall also meet the following physical qualifications:

a. Vision of at least 20/30 Snellen in one eye and 20/50 in the other, with or without corrective lenses.

b. Ability to distinguish colors, regardless of position, if color differentiation is required for operation.

c. Adequate hearing, with or without hearing aid, for the specific operation.

d. Sufficient strength, endurance, agility, coordination, and speed of reaction to meet the demands of equipment operation.

e. Evidence of physical defects or emotional instability which could render a hazard to the operator or others, or which in the opinion of the examiner could interfere with the operator's performance, may be sufficient cause for disqualification. In such cases, specialized clinical or medical judgments and tests may be required.

f. Evidence that an operator is subject to seizures or loss of physical control shall be sufficient reason for disqualification. Specialized medical tests may be required to determine these conditions.

g. Operators and operator trainees should have normal depth perception, field of vision, reaction time, manual dexterity, coordination, and no tendencies to dizziness or similar undesirable characteristics.

Upon successfully completing the written, practical and physical requirements, the operator shall be given an Operator's Qualification card (see attached). This card must be carried by the operator whenever he is operating equipment and must be surrendered upon his termination of employment.

This card must be carried at all times when operating equipment

Card Number ____________ Date Issued ____________

Operator's Name (Print)

Permanent Address (Street, City, State, Zip)

Social Security Number

Phone

( )

Issuing Official's Signature:

Operator's Signature

The holder of this card is qualified to operate the equipment listed (subject to restriction)

RESTRICTION: MUST WEAR GLASSES: YES NO
TYPE EQUIP	CAPACITY/ATT.	NAME/TITLE LICENSING OFFICIAL	EXP. DATE



THIS CARD IS PROPERTY OF: Standard Maintenance Company, LLC 1898 Vanderhorn Dr. Memphis, TN 38134

FORKLIFT OPERATOR’S QUALIFICATION

1. Purpose

The intent of this procedure is to verify an operator’s ability to safely operate a forklift before actually beginning work.

2. Before an employee is permitted to operate any forklift, he/she shall pass the “Forklift Training and Test” and the “Operational Exam”. In addition, he/she shall also meet the following physical requirements:

a. Normal or corrected vision to 20/30.

b. Adequate hearing with or without hearing aid.

c. Sufficient strength, endurance, coordination and reaction speed to meet equipment operation demands.

3. Operational exam should include maneuverability, ability to pick up and place:

a. Pipe

b. Pallet

c. Equipment

and to properly secure a forklift for overnight.

Forklift Training

Introduction

As a professional forklift operator, you make judgement calls all day – each of them geared to keeping your load and lift truck stable while you work safely and efficiently.

Each year accidents involving power industrial trucks result in more than 100 deaths and over 38,000 injuries. Operators must have training to safely operate powered industrial trucks.

Each shift, after you inspect your forklift, you deal with operating conditions and special hazards. These vary with the work you’re doing and can change many times a day.

Some of the issues you face include surface conditions, various loads and stability, proper load manipulation, stacking and unstacking, vehicle and pedestrian traffic and situations like narrow passages or restricted access. Then there are special conditions related to locations or environment, plus all the rules of operating safely.

A professional forklift operator avoids accidents by:

Understanding forklift design, controls and instrumentation.

Conducting a complete pre-inspection before each day’s use.

Understanding forklift stability and the factors that affect it.

Design of the Forklift

Forklifts are also called “powered industrial trucks”. They come in a variety of sizes and designs and may operate on propane, gas, or diesel fuel.

Each forklift is designed to perform specific task in set situations and has the controls, attachments, tires and lifting capacity to perform its assigned job.

All forklifts have one common item – forks or attachments for lifting loads –

Parts of the Forklift

The parts of the forklift include:

MAST -- The upright section that contains a set of tracks that house ball bearing rollers and the chains It tilts forward and back, and may travel side to side.

Carriage – Housed within the mast, it contains the rollers that allow the load to be moved up and down.

Backrest – Mounted to the carriage, it keeps the load from falling back when forks are tilted back.

Overhead guard – Keeps falling objects from hitting the operator but is NOT strong enough to withstand the force of a heavy load.

Only the basic design of forklifts are the same. In use, forklifts have different controls, weight capacities and restrictions on where they can operate. Refer to the manual of each forklift BEFORE you attempt to operate it.

Forklifts and Cars

A forklift is not like a car. It steers differently and has different controls. Most forklifts steer from the rear. When you turn the rear end swings in a circle around the drive wheels. (Usually the front).

The truck is less stable when turning because of the front drive wheels support most of the load. You also have less steering control when turning, especially when the forklift is loaded.

The forklift’s steering and drive mechanism also makes it difficult to stop quickly and dangerous to swerve – for example – to avoid a pedestrian.

Forklifts also differ from cars in other ways. They operate equally well in forward or reverse, but steer differently in each direction. They also have blind spots, especially when loaded.

Controls and Instruments

The controls and instruments in a forklift may vary by manufacturer, design, and rating. Refer to the operators manual for the specific truck you are using.

Some forklifts have a seat belt for the operator’s use. If a seat belt is available you MUST use it.

Typical controls for a forklift include:

A wheel or other device for steering

A key or switch for starting

A service brake and parking brake

An accelerator or other device for controlling speed

Levers to control forks

A horn, and a warning device (flashing light or buzzer)

Meters for monitoring conditions

Pre-use Inspection

The pre-use inspection takes only a few minutes, and must be done a least daily or at the beginning of each shift. Use the form included here to do the check. Additional forms are available from the safety department.

If anything is defective, shut down the forklift and report the problem. Turn key over to job supervisor.

GAS OR DIESIL POWERED EQUIPMENT INSPECTION FORM

Equipment Number:

Operator's Name:

Project Location:

Date:

HOUR METER/SPEEDOMETER READING - _________________________

Check () boxes accordingly ( ) OK ( ) Needs attention or repair

VISUAL CHECKS:		OPERATIONAL CHECKS:
	Engine Oil Level		Horn
	Radiator water level when cold		Steering
	Fuel level		Service brakes
	Obvious damage and leaks		Parking brake
	Tire condition		Hydraulic controls
	Head and tail lights		Directional signals
	Warning lights		Backup alarm
	Hour meter/speedometer		Fire Extinguisher
	Other gauges and instruments
	Current maintenance sticker

Comments: (Explain all items needing attention or repair.)

Forklift Stability

Knowledge of the forklift – things such as stability, balance, capacity and visibility – separates the top-flight operator from the rest. The professional knows that every load and every situation is different and that every lift and carry must be evaluated and planned.

The design of the forklift is based on a stability triangle. The front axle acts as the base of the triangle and supports the weight of the loads. The sides of the triangle meet at the point where the forklift steers.

Keeping the downward force of the load in the triangle keeps the forklift stable and the load from falling. Allowing the load to move outside this area makes both the load and truck both less stable – and subject to tipping, rolling, or dropping the load.

In real life, your forklift and load become less stable when:

The load is raised

When you turn

On slopes, either front to back or side to side

When tilting the load forward, back or side to side

On uneven surfaces or rough terrain

On every carry, you need to decide if your stability will be affected by:

The load and it’s weight and shape

The route and conditions along the way

The destination and the maneuvers needed to set the load down.

You can increase your stability by carrying a smaller load. You should reduce your load if:

The load is tall, wide, or oddly shaped

If a high lift is involved or the route of travel is rough

If the load can’t be centered or carried close to your drive wheels

If you have to make tight turns or travel up or down a slope

To keep the load stable you should:

Space your forks as far as part as possible

Make sure the load won’t shift during travel

Transfer loads on broken pallets or containers to undamaged ones before moving the load

Wrap or strap loose items or loads

Know the rated load capacity of your truck and NEVER exceed it.

Some of the questions to ask…..

What is the rated load capacity of my truck?

Is this load well within the capacity limits?

Will the shape of the load affect my stability?

Will the load affect my visibility?

Do I need to split up the load?

Do I need to drive in reverse?

What hazards are along the route?

What turns will I have to negotiate?

Are there ramps, slopes, rough ground or obsticals?

What about the destination?

Can I get close enough?

Can I pull straight in?

Is the area free of overhead dangers? (such as power lines, pipe or equipment)

Surface Conditions

As an operator it’s your job to examine the surfaces where you will be using the truck. Is it strong enough to support the truck and load? What about loose objects, bumps and other surface hazards?

No matter what the surface, speed is a big issue. In a plant, other area where people are present, or with any load – THE MAXIMUN SAFE SPEED IS NO FASTER THAN A FAST WALK ! Speed and surface conditions affect the stability of your forklift and load.

Lifting a Load

To pick up a load:

Square up on its center and approach it straight on

Stop with the tips of your forks about one foot from the load

Level the forks and slowly drive forward until the load rest against the mast

Lift the load high enough to clear and tilt the mast back slightly to a traveling position

Look over both shoulders to make sure it’s safe to back up

If there’s another load in front of the one you are lifting, lift without tilting.

The traveling position is as close to the surface of travel as possible, usually with an inch or two under the heel of the forks and four to six inches at the tips, with the load resting against the mast.

Putting down a Load

To put down a load:

Square up and stop about a foot away

Drive forward until you are about halfway into the loading area

Stop

Level the forks and drive the rest of the way in

Lower the load

After the load is seated, lower the forks slightly

Look over both shoulders and back out slowly

A few points to remember:

Make sure the area is clear of people.

Stop before raising or lowering forks.

Look over both shoulders before you back out

Never travel or turn with the load elevated.

Lift the load only high enough to clear obstacles and lower as soon as possible.

Traveling Tips

Many accidents involving forklifts occur when travelling. When driving a forklift you should:

Tilt the load backward slightly.

Slow down and sound your horn at corners, intersections and places with a limited view.

Drive at a slow steady pace.

Slow down for turns.

Drive in reverse if your vision is obstructed.

Yield to pedestrians – they always have the right of way.

Never drive up to anyone standing in front of a fixed object.

Never allow anyone to stand on your forks or lift people with an approved platform.

Never allow anyone to walk or stand under your forks, loaded or empty.

Special Hazards

During your work with the forklift, you may encounter special hazards. These hazards include hazardous locations, activities and environments.

Hazardous locations:

Some forklifts cannot be used near food products. Others cannot be used around chemical vapors, or grain, fiber, or metal dust, which can explode. Your employer will supply the right type of forklift for your area of work. Your job is to know the restrictions and to never operate the forklift in an environment where it is not intended for use.

Hazardous activities:

When operating on ramps or slopes:

Stay well back from the edge.

Never turn around on the slope.

Drive with your load on the uphill side.

(This means you drive up slopes with the load in the front and drive down slopes in reverse. When you have no load, back up a slope and drive down forward.)

When working on docks:

Make sure dockboards or bridgeplates are properly secured and strong enough to handle the weight of the truck and load.

Keep the bridge or dockboard as level as possible.

Make sure the rail cars or trailers won’t move when you drive on.

Hazardous environments:

When working in an enclosed area, carbon monoxide may build up. Make sure to have adequate ventilation.

When moving materials, make sure you know the possible hazards of them. Read the MSDS sheet.

Operating Safely

Being a forklift operator means you know and follow the basic safety rules in every situation:

Buckle your seat belt when you’re in the truck.

Never leave the truck until you lower the lifting mechanism, put the controls in neutral and set the brake.

Never modify forks or attachments.

Never give rides or let anyone stand on the forks.

Keep your arms and hands inside the truck.

Keep the controls and your hands clean and dry.

Never block doors or emergency equipment.

Never turn on a slope.

Don’t raise, lower or tilt a load while moving.

Summary

Operating a forklift is a dangerous job if not done correctly. It takes a lot of work and dedication to become an accomplished forklift operator. The pros know that every truck, every situation, and every load is different. Practice the safety procedures you have learned.

Operator Certification

Operating a forklift requires special skills. OSHA requires a high level of training, re-training and certification for everyone that operates a forklift – and not everyone can qualify.

Forklift operators are required to have classroom and practical training for the certification to operate a forklift. You will have a Quiz of forty questions that you must get thirty correct. Then you will go out and operate a forklift in the presence of the instructor that will put you through a practical operating test. If you pass you will receive a certificate and wallet card. A copy will be placed in your personal file. The training is valid for three years, unless one of the following:

Operator fails to follow these guidelines. (results in revocation of certification).

Operating conditions change (different type of truck, location, etc.).

Accident or near miss.

Your certification my be revoked by the following:

The safety department

Operator trainer

Jobsite supervisor

Forklift Operator Quiz Pass Fail

NAME:_______________________ Date:___________________

SSN:_________________________ Company:_________________

Trainer’s Name:_____________________________________

Circle the correct answer T = TRUE F = False

T F 1. Although forklift injuries are common, only a few people are killed

in forklift accidents.

T F 2. All forklifts operate on battery power.

T F 3. Each forklift is designed to perform specific tasks in set situations

and should never be used in any other way.

T F 4. The mast on a forklift is the upright section that contains a set of

tracks that house ball-bearing rollers and chains.

T F 5. Forks are mounted to the mast.

T F 6. The overhead guard is designed to protect you from a heavy

load that falls on your truck.

T F 7. OSHA requires that you be qualified for each type of forklift and each

kind of work situation you encounter.

T F 8. With a littler practice, anyone that can operate a car can operate

a forklift because both work the same way.

T F 9. Because of the weight of the load a forklift is more stable while

turning than when being driven straight ahead.

T F 10. When doing work that requires you to be on and off the forklift

you are exempt from wearing a seat belt.

T F 11. Although the basic components may be the same, the exact

controls and instruments vary from one forklift to another.

T F 12. All forklift trucks have a brake and accelerator pedal.

T F 13. You should set aside a hour each week to do the required

pre-use inspection.

T F 14. Smoking around a gasoline powered forklift is dangerous

but it’s ok to smoke around a propane truck.

T F 15. It’s ok to leave a truck running while you refuel it.

T F 16. Part of the pre-use inspection involves checking all gauges,

indicators, and warning lights after you start the forklift.

T F 17. The stability triangle is the part between the forks.

T F 18. You must evaluate your load, route and destination before

you begin a lift.

T F 19. A forklift is less stable on slopes, either front to back, or side to

side, or when tilting a load.

T F 20. All forklift operators are evaluated when they have an accident

or when conditions change.

T F 21. Using good judgement on every load and carry is the mark of a

professional forklift operator.

T F 22. A bump or uneven floor is only dangerous if you are speeding.

T F 23. Load size and weight affect forklift stability and must be

monitored by never exceeding the rated capacity.

T F 24. Load shape and attachments do not affect forklift stability.

T F 25. Individual items on a load should be secured if they are

breakable but not if they won’t break if the load falls.

T F 26. When approaching a load you should always stop about a foot

from the load then adjust the height of your forks.

T F 27. In the traveling position your forks are about one foot off the

floor.

T F 28. When stacking you should place the load squarely on the stack

or the whole stack could fall.

T F 29. Driving with obstructed vision is allowed if you are moving less

than twenty feet.

T F 30. A safe speed is about the same as a fast walking speed.

T F 31. Pedestrians never have the right of way.

T F 32. The operator is responsible for not allowing anyone under the

forks.

T F 33. Once you are certified, there are no restrictions on where you

can operate.

T F 34. You can safely turn around on a ramp if it’s more than two

forklifts wide.

T F 35. A loaded forklift traveling down a ramp or slope should always

be driven in reverse.

T F 36. An empty truck should always back up a slope.

T F 37. Edges on ramps and flatbed trailers are one of the big hazards.

T F 38. Always secure trailers and rail cars before you drive on them.

T F 39. Carbon Monoxide fumes can build up in an area with poor

ventilation.

T F 40. Operators must fasten their seat belts as soon as they get into

the truck.

Answer key

F 1.

F 2.

T 3.

F 4.

T 5.

F 6.

T 7.

F 8.

F 9.

F 10.

T 11.

F 12.

F 13.

F 14.

F 15.

T 16.

F 17.

T 18.

T 19.

T 20.

T 21.

F 22.

T 23.

F 24.

F 25.

T 26.

F 27.

T 28.

F 29.

T 30.

F 31.

T 32.

F 33.

F 34.

T 35.

T 36.

T 37.

T 38.

T 39.

T 40.

CRANE OPERATOR'S QUALIFICATIONS TEST

1. Q. Prior to exiting the crane cab, the operator must do the following:

_____________________________________________

A._ (Land any load, disengage the clutch, lock the swing, travel or other brakes, set the controls to neutral, secure the crane against travel.)

2. Identify the following signals.

Answers:

(use whip or aux. hoist)

(move slowly)

(lower boom)

(lower boom and raise load)

3. Q._ The hydraulic system shall be checked for correct level and leaks.

A._ (Daily)

4. Q._ Ropes require inspection if they have not been in service for a period of _____________.

A._ (One month)

5. Q._ After the crane is started, the first thing the operator shall check is ________________.

A._ (The gauges)

6. Q._ When the block or ball is raised into the boom point, it is called ________________.

A._ (Two blocking)

7. Q._ Under the conditions below, can the 4,000 pound transformer set using 7'-0 off boom?

A._ (No)

8. Q._ No less than ____ full wraps shall remain on the drum when the hook is in the extreme low position.

A._ (two)

9. Q._ Which of the following is acceptable for dead ending rope in a socket?

A._ (All)

10. Q. Cranes shall be kept a minimum of 10 feet from overhead lines. (TRUE OR FALSE)

A. (True)

CRANE OPERATOR'S QUALIFICATIONS TEST

Name_____________________________________ SSN________________________________

1. Q. Prior to exiting the crane cab, the operator must do the following:

_________________________________________________________

2. Identify the following signals.

Answers:

__________

3. Q._ The hydraulic system shall be checked for correct level and leaks. _____________

4. Q._ Ropes require inspection if they have not been in service for a period of _____________

5. Q._ After the crane is started, the first thing the operator shall check is ________________

6. Q._ When the block or ball is raised into the boom point, it is called ________________

7. Q._ Under the conditions below, can the 4,000 pound transformer set using 7'-0 off boom?

______ Yes _______ No

8. Q._ No less than ____ full wraps shall remain on the drum when the hook is in the extreme low position.

9. Q._ Which of the following is acceptable for dead ending rope in a socket?

10. Q. Cranes shall be kept a minimum of 10 feet from overhead lines.

______ True ______ False