FORKLIFT TRUCK

OPERATORS
HANDBOOK
This book belongs to:

________________________________

Date Received:

________________________________

Employee Signature:

________________________________

Issuing Manager:

________________________________

Managers Signature:

________________________________

Published: March 2018

Review Date: March 2022

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 BASIC RULES

This handbook outlines the basic rules for

operating all types of High Risk forklift
equipment and associated attachments. This
handbook should be read in conjunction
with the DIC ANZ Forklift Policy Document.
The Handbook does not contain ALL rules
for all areas. Additional S.O.P instructions
may be required by specific tasks,
areas/departments. Please ask your Team
Leaders, Supervisors or Managers for
details.

DIC ANZ has established these rules and will

enforce them for the safety of employees
and visitors, forklift operators and
pedestrians. Non-compliance may result in
disciplinary action up to and including
termination of employment

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 TABLE OF CONTENTS

Hierarchy of Hazards Control ....................................... 6

1. Licensing .................................................................. 8
2. Training .................................................................... 9
2.2 Refresher Training ........................................ 10
3. Operator Checks ................................................... 11
4. Forklift Operational Rules .................................... 14
4.1 General Rules................................................. 14
4.2 Parking................................................................ 16
4.3 Loads............................................................... 16
4.4 Speed .............................................................. 18
4.5 Pedestrians ..................................................... 19
4.6 Motor Vehicles on Site .................................. 19
4.7 Vision Rule ..................................................... 20
4.8 Fire Evacuations ............................................ 20
4.9 Disciplinary Action ......................................... 21
5 LPG Handling......................................................... 22
6 Forklifts and Tag Out ........................................... 24
7 Attachments .......................................................... 25

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 7.1 Slippers ........................................................... 26
7.2 Drum Clamps ................................................. 27
7.3 Jib crane ......................................................... 28
7.4 General Rule for all attachments ................ 29
8 Stacking Rules ....................................................... 30
9 Loading/Unloading ................................................ 31
10 Reporting of Faults ........................................... 33
11 Electric Walk Behind Units ............................... 35
12 General Safety Rules ........................................36
13 Connecting/Disconnecting Procedures for
Electric Forklifts ............................................................ 38
14 Contractors on Site ........................................... 40
14.1 Maintenance Contractors ............................... 40
14.2 Independent Contractors.......................... 40
15 Forklift Checklist ................................................ 43
16 Electric Work Platforms ....................................44

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 Hierarchy of Hazards Control

Do not simply choose a control method

because it is the easiest to fastest to
implement.

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 Forklift Site Performance –
Self Assessment
ASSESS THE RISK!!!
What could go wrong?
What is the worst thing that could happen, if
something does go wrong?

ANALYSE HOW TO REDUCE THE RISK

Do I have the necessary training to use
various attachments and controls on the
forklifts and knowledge to do the job safely?

ACT TO ENSURE SAFE OPERATIONS!

Take the necessary action to ensure the job
is done safely, follow written procedures, ask
for assistance, if needed!

DO NOT PROCEED UNLESS EVERYTHING IS

SAFE!

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1. Licensing

Where an employee or contractor is required to

operate a forklift truck the Company will meet the
following obligations:

1. Ensure the employee/contractor knows and

understands the DIC ANZ Policies
2. Provide information, instruction, training and
supervision
3. Ensure the employee/contractor is given the
opportunity to learn and acquire the
necessary skills and experience in the
operation of the forklift truck types.
4. Arrange biannual refresher training VOC
(Verification of Competency) training, to
current standards of licence knowledge and
practical operation of high risk equipment.
5. Provide training for the use of attachments
used on the forklift
 This is achieved through attachment
knowledge and demonstration by the
candidate that all practical competency is
reached during training.

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2. Training

2.1 Forklift Operators Induction

 Employees/Contractors new to DIC ANZ sites
who have been newly appointed to drive a
forklift truck must have completed the DIC
induction which includes the forklift induction
section.
 The induction shall include this operator’s
handbook. The operator will also be required
to sign the forklift policy.
 Demonstration of procedures, where
appropriate, shall be provided by a
competent employee, with the task being
undertaken by the inductee to show
understanding.
 An operator MAY NOT operate a forklift
without first SATISFACTORILY completing
the forklift operator’s induction.

No unlicensed employees, visitors or others may

operate a forklift on a DIC Site.

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2.2 Refresher Training
 Employees shall undertake refresher training
every two years
 At other times, if instructed by management

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3. Operator Checks
 An employee/contractor must confirm the
forklift has been checked daily, using the
appropriate DIC ANZ checklist for that type
of forklift before operating.

 Whenever a driver identifies problems with

the operation of the forklift, as indicated on
the provided CHECKLIST, the forklift must be
tagged out, the key removed and the fault
reported immediately to your Team
Leader/Supervisor/Manager.
o Where a fault is found the machine is
to be tagged Out of Service, it cannot
be used unless the fault has been
repaired. If a fault is reported for any
item the forklift MUST be tagged out.
Exceptions to this are the headlights
and lights, where fitted, during day
light shifts, however must be tagged
out for use at night.
o Where a fault has been reported the
Maintenance Manager/ Team
Leader/Supervisor will arrange for the
forklift to be repaired

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 o Only an approved repairer can repair
and return a forklift to service or
remove a tagged-out forklift

 The signed copies of the DAILY CHECKLISTS

are to be filed and kept by maintenance or
management.
 Electric forklifts MUST have battery fluids
topped after charging then turn off all
charges prior to leaving the area.
 Team Leaders/Supervisors are responsible for
ensuring the checklists are completed
correctly, on time and given to maintenance
or managers to file.
 The site manager is responsible for ensuring
all reported faults are identified and repaired.

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Page 13 of 48
4. Forklift Operational Rules

4.1 General Rules

 Scrubber units to be flushed and fitted at the
start of each shift.
 No mobile phones, I-pods, mp3 or other
mobile music devices can be worn at any
time onsite.
 Forklifts to be operated at WALKING PACE.
 Correct PPE (Personal Protective Equipment)
to be worn.
 No hearing protection can be worn when
operating a forklift.
 Seat belts, when fitted, MUST be worn.
 Forklifts must not enter Class 3 areas, which
are not Flameproof units
 Reversing procedures – looking over each
shoulder MUST be conducted prior to
reversing. Further watching is also
necessary whilst reversing. Mirrors can also
be used while reversing.
 Always stay in the rated capacity of the
forklift.
 Lift with the mast vertical or tilted slightly
back – NEVER forward.

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 Watch for rear end swing when manoeuvring
 Never tilt forward an elevated load, especially
when bins, vessels or tanks are being lifted –
they will slide off the fork arms.
 Only the operator to be on the forklift – NO
passengers.
 Forklifts are never to drive over open drains,
potholes, electrical wires, across inclines or
speed humps.
 Always sound the horn at door entrances or
blind corners.
 When forklifts are not in use remove keys, or
lock the controls.
 Pedestrians have right of way always.
 Never travel with elevated loads, lower loads
below front axle height prior to travel or
operate with the load close to the ground.
 Operators must have their licences available
on request always.
 If you have prescription glasses or contact
lenses they must be worn always.
 Obey all signs onsite including any stop
signs.

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4.2 Parking
 Diesel forklifts may be left running only if
lock out devices are fitted.
 NEVER park in front of any doorway,
entrance, emergency exit, firefighting
equipment, first aid station or any
passageway which is used by persons
requiring access.
 Park on level ground, lower forks completely
and tilt slightly forward, so that tips are in
contact with the ground.
 Place machine in neutral.
 Switch off engine or lock the movement
control.
 Apply handbrake.
 Park at the end of shift at designated
locations.
 Removal of keys must be done whenever
leaving forklifts unattended at the end of a
shift.
 If you have been issued with keys keep these
secure always. If keys are held onsite ensure
they are secured at the end of the shift.

4.3 Loads
 All loads must be carried safely at ALL times.

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 When carrying bins, tanks or any attachment
not specified as a forklift attachment ensure
full back tilt is applied – remember if
emergency breaking is required the load may
side off the forklift tynes if full back tilt is not
applied.
 Do not travel with raised loads.
 Never travel forward where vision is blocked
by the carried load you MUST travel with
forklift in reverse.
 If travelling in reverse a spotter can be used
if required
 Be careful if handling long lengths or bulky
tanks. Watch rear swing and use an
additional operator as a guide if necessary.
 Keep pallets and any load against the vertical
face of the forks.
 Keep load balanced laterally.
 Spread forks according to load width, ensure
any load is balance evenly
 Lower all loads slowly and STOP gently.
 All objects of irregular shape to be securely
lashed if necessary to forklift backrest.
 Do not park the forklift with the tynes in an
elevated position.
 Do not lift loads with only one fork arm.

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4.4 Speed
 General forklift operating speed is WALKING
PACE for entire site.
 When entering a building or doorway
entrance check to ensure the area is clear,
and sound the horn before proceeding.
 If coming from a bright, outside location to a
dark warehouse area – take extra care for
eyes to adjust and remove sunglasses.
 Inside manufacturing locations extreme care
is needed when manoeuvring forward or
reversing. It MUST be done slowly and
carefully.
 When operating in wet and slippery
conditions turn and brake carefully, observe
the site speed limit. Sudden breaking in wet
conditions increases the risk of a loss of
control.

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 4.5 Pedestrians
 Pedestrians have always got the right of way.
 Forklifts are not allowed to operate in isles if
pedestrians are present in the row or the row
opposite the racking that your loading or
unloading.
o The only exception to this is during
stocktakes – in this case a briefing
must be given to all staff involved.
o Even during stocktakes do not operate
in opposite rows, this is to eliminate a
risk of injury should an object falling in
the opposite isle.

4.6 Motor Vehicles on Site

 Forklifts have the right of way; however, you
must ensure eye contact is made with any
driver of a vehicle to ensure they have
observed your forklift.
 Care must be taken in high traffic areas
where motor vehicles and forklifts may be
operating.
 Ensure you use the horn when approaching
all vehicles so they are aware of your
presence.
 All motor vehicles must obey the site 5Kph
speed limit.

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4.7 Vision Rule
 If your vision is obstructed, obscured at a
corner reduce speed and proceed with
caution, use your horn to alert any
pedestrians/vehicles, check the area for any
mirrors or warning lights. Proceed slowly
and cautiously.
 Watch for overhead clearances.
 For better vision, drive in reverse with all
bulky loads. Use a nominated guide if
required.

4.8 Fire Evacuations

 If a fire alarm is activated while you are
operating a forklift, park the forklift clear of
any evacuation pathway and ensure the
driveways are clear.
 Do NOT park in front of emergency exits for
firefighting equipment.
 Watch out for pedestrians evacuating
buildings.
 **** ON THIS ONE OCCASION ONLY***
 Make sure forks are lowered to the ground,
apply the hand brake.
 The forklift keys can be left in the forklift;
flameproofed diesel forklift lockouts do not

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 need to be secured, flameproofed diesel
forklifts can be left running.

4.9 Disciplinary Action

 Noncompliance with these rules may result in
disciplinary action.
 This may be in the form of a verbal or
written warning and can lead to dismissal.
 In the case of contactors/casuals – a request
to leave the site or exclusion from the site
and premises may be applied.
 DIC ANZ has a drugs and alcohol policy
which specifies the limits and procedures
around personnel who may be under the
influence of drugs or alcohol.
o If you are using prescribed medication
that causes drowsiness, or comes with
a direction not to operate heavy
machinery and / or motor vehicles,
you must advise your manager or the
HR department before commencing
work.

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5 LPG Handling
 Cylinders must be in an appropriate and
designated cage area. No cylinders are to be
stored elsewhere on-site.
 Wear the gloves provided while exchanging
cylinders to avoid freeze burns.
 As flammable gas may leak during the
changeover of gas cylinders ensure you’re in
a well-ventilated location and no ignition
sources exist (naked flame, angle grinding,
welding, hot work)
 Check the date on the cylinder is within 10
years.
 Tag out any out of date cylinders,
immediately report this to your Team
Leader/Supervisor.
 Remove plastic cap from valve filling nozzle.
 Unstrap empty cylinder lift carefully.
 Lift full cylinder and place into cradle, turn
the valve to face vertical. In this position,
your gauge accurately shows liquid level in
cylinder.
 Leaks – if you have a leak
o TURN OFF TAP ON BOTTLE
o DO NOT ATTEMPT TO REPAIR FAULT
o DO NOT ATTEMPT TO START ENGINE

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 o Tag out the forklift
o Remove the key
o While waiting for gas to dispense go
and get Team Leader/Supervisor
 Turn off LPG tank after parking forklift.

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6 Forklifts and Tag Out
 Tag outs are available and should be used if
any faults are found with your forklift. This
is not limited to initial daily check list, if any
fault develops while driving during your shift.
o TAG IT OUT
o Remove the key
o Report the fault to your immediate
Team Leader or Supervisor.
 This tag out may be applied to attachments,
and charging stations
o Please refer to the tag out policy

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7 Attachments
 Attachments may be used on-site daily.
These are fitted to forklift trucks to enable
them to undertake specific lifting tasks, other
than load-shifting of standard palletised
loads. Examples of these attachments
include:
o Slippers
o Drum clamps
o Jib cranes

 Man up cages can only be used on-site in

Auburn by the authorised operators and on
an approved forklift. This is a high-risk
attachment not available to general
operators.
 Whilst these attachments increase the
versatility of the forklift, they also affect the
centre of gravity and the lift capacity of the
forklift.
 Operators therefore, need to be aware of the
restrictions placed on a forklift when
attachments are used.
 Operators must also ensure that the
attachments are only used on appropriately

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 designed forklifts (refer to Data plates) and
that they are properly fitted and secured with
chains, pins, locks and designed under the
ANZ standard.

7.1 Slippers

 Tyne slippers may be fitted if necessary to

increase the reach of the truck, however, the
use of such device reduces the lift capacity of
the forklift. Drivers must be aware of this
de-rated capacity of the truck before
attempting to lift loads.
o Completed inductions
o Training refresher courses
o Training to become authorised users
of this attachment.
o Please refer to your forklift load plate
to ensure the change in load centre
distance is within the correct weight
limit for your forklift
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7.2 Drum Clamps

 In All cases - fit safety chain and secure with

‘D’ shackles.
 NOTE: drum clamps can have various drum
securing systems please refer to your specific
attachment being used for a full operating
procedure.
 The use of this attachment requires the
operator to refer to the SOP specific to the
attachment being used.
 The operator must also have:
o Completed inductions
o Training refresher courses
o Training to become authorised users
of this attachment.

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7.3 Jib crane

 This unit makes the forklift a portable

crane.
 This is normally used by operators to
raise bulk bags and can be used by
contractors for moving equipment.
 The use of this attachment requires the
operator to refer to the SOP specific to
the attachment being used.
 The operator must also have:
o Completed inductions
o Training refresher courses
o Training to become authorised
users of this attachment.
o The use of any slings when using
this attachment must be approved
lifting devices and have correct
load limits attached

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7.4 General Rule for all attachments
 Check the forklift Data plate to ensure it
is a machine approved to use the
specified attachment.
 Inspect the attachment, ensure if good
order.
 Fit the attachment to fork arms without
force.
 Secure the slipper with pins, chains on
others.
 Make sure that attachments are always
returned to their storage location. Do not
just unhitch and leave it where last used.
 In all cases the attachment securing
system must be in good working
condition for the attachment to be used.

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8 Stacking Rules
 Use care when high stacking – watch for
falling stock.
 When loading racks, generally do not top
load the racks when the centre and bottom
locations are only lightly filled or empty.
 Do not leave a load on a rack or stack that
appears unbalanced or unsafe.
 If block stacking pallets
 Make sure the pallets can be top loaded
 Make sure the location is flat and suitable
 Don’t top load past a stable height
 When lowering loads on top, do so gently.
 Do not leave a load on a rack or stack that
appears unbalanced or unsafe.
 Unloading Pallets – (transferring on site or
unloading trucks) – remember always
ensuring the load is stable and within the
load limits of the forklift.

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9 Loading/Unloading
 Loading and unloading trucks with the use of
a forklift must be undertaken with attention
to Safe Work practices. The following Safe
Work practices will always be followed:
 Make sure that the forks are centred
o When they are entering a pallet or
metal pockets.
o Don’t travel with non-centred side
shift.
 Make sure the pallet or load in general is not
damaged.
 Make sure the stability and weight is in
accordance to your chosen forklift.
 Securely insert forks so load is up to vertical
face of fork arm prior to lifting.
 Always stop and lower loads as soon as you
clear vehicle.
 Always lower to as close to ground as
possible.
 Carry the load to the stacking or unloading
position and then raise the load in a vertical
mast position.
 Keep travel distances to a minimum.
 Do not travel with raised loads.
 Do not turn with raised loads.

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 Always reverse by first conducting a both
shoulder and head check before moving and
either continue to watch in reverse or with
unit fitted with scrubber units – use your
reversing mirrors
 Do not stand on forks or on a pallet on the
forklift, when loading or unloading, they are
not designed to be used as a step or work
platform.

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10 Reporting of Faults
 If an operational fault occurs at any time, the
following procedures take affect:
o If the forklift has a fault and is safe to move,
take it to a clear area away from production
work areas:
o Remove the key
o Tag out machine
o Report fault to your supervisor or Team
Leader

 If forklift is unsafe to move:

o Leave it where it is
o Tag out the machine
o Remove the key
o Report fault to your supervisor or Team
Leader

 Tag out requires the company identity tag to

be put on the steering wheel or prominent
location.
 Your manager or maintenance will arrange
for repairs to be completed.
 Any communication regarding repair of
forklifts needs to be recorded for reference.

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 The manager or maintenance will action
repairs and make sure no further use will
take place. They will authorise the return to
service of the forklift after the repair.

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11 Electric Walk Behind Units
 Training and Accreditation - Only operators
trained to use the electric hand forklifts and
authorised by the company are to use the
equipment.
 This authorisation may be only for use in a
specific area and for special tasks only.
 The walk behind forklift requires a daily
checklist to be conducted prior to use – refer
to supplied checklist.
 This checklist is to be returned to Team
Leader/Supervisor, then given to the
manager to file.
 Always keep hands inside handle grips.
 Never walk backwards with machine, always
turn around and let forklift follow you. This
way if machine malfunctions you don’t put
yourself at risk.
 Refer to the SOP for the safe operation of
this equipment.

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12 General Safety Rules
 Ensure your feet remain within the forklift
footwell
 Check area for any hazards.
 Check for pedestrians or vehicles in your
working area.
 Avoid sudden braking (especially in the wet)
 Always maintain control of the forklift
 Avoid running over loose objects on the floor
 Only licensed operators can use forklifts or
attachments.
 No riders allowed on forklift
 Do not travel to closely to pedestrians or
other vehicles or forklifts
 Always watch for pedestrians – indoors and
outdoors.
 Sound horn when approaching blind corners,
other vehicles or congested areas.
 Keep fork tynes low close to the ground at all
times.
 Always position tynes evenly.
 Always check load is stable.
 Always check load is secure.
 Watch for overhead obstructions e.g.
doorways; sprinklers, electrical wires or
signs.

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 When parking keep forklift clear of buildings,
doors, ramps or dock areas.
 When manoeuvring ensure you monitor any
rear-end swing to avoid hitting an object.
 USE Forklift in authorised areas ONLY – if in
doubt simply ask your Team
Leader/Supervisor.
 Only approved flameproof forklifts can be
used in hazardous area’s
 These can be identified with a ZONE 1 label
 If in doubt see your supervisor or team
leader
 When travelling up and down ramps the load
must be facing forward (uphill) always.
 Do not push objects with your forklift
 Do not use attachments for anything other
than their intended use.

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13 Connecting/Disconnecting
Procedures for Electric Forklifts
 Before connecting or disconnecting batteries
to charges make sure the charger is turned
off at the mains power.
 Before charging take machine to an allocated
location and use the appropriate charger
available (note not all chargers are
universal).
 Before connecting battery cables, switch off
the forklift, remove key, set hand brake and
lower the tynes to ground level
o Please note: take care when parking the
forklift ensure the forklift tynes do not
damage the charging station.
 Check battery terminals are clean and free
from corrosion.
 This means reach units require you to open
forward the battery carriers prior to charging.
 The charging location has been chosen for
correct ventilation of the Hydrogen gas which
is given off during charging.
o Observe this as hydrogen gas is highly
flammable and can cause an explosion or
fire.

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 Battery levels need checking and should be
topped up with water.
 After charging and not before.
 Note: Failure to keep battery levels topped
up with water will damage the battery, if
they charge dry.

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14 Contractors on Site

14.1 Maintenance Contractors

 Contractors must have DIC authorisation
prior to operating a company forklift truck or
attachment.
 To obtain authorisation,
o They must have completed a site
induction
o The contractor must provide a copy of
their forklift license
o Agree to abide to all DIC ANZ site
regulations
o Sign a copy of this policy handbook.
o Sign a copy of the forklift policy
 All staff on site will be requested to report to
their Team Leader/Supervisor/ Manager any
breaches of this handbook, if observed by
contractors.

14.2 Independent Contractors

 Unlicensed Contractors, including truck
drivers etc, are NOT authorised to use forklift
trucks or attachments. Should it be
necessary to have materials/equipment

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 moved they should advise their DIC Australia
contact person who will arrange for a
company forklift driver to complete the load
shifting task.
 Contractors CAN NOT bring their own forklifts
or equipment on site without the permission
of the relevant site manager.
 If a contractor requests to bring their own
forklift onsite:
o The contractor must complete a company
approved operational checklist and lodge
a copy with the site manager prior to
using their Forklift truck on site.
o Any forklift attachments bought on site
must be inspected by the WHS Manager
or alternate Authorised Person on site
prior to use.
o All forklift attachments must have data
plates listed on the forklift which they will
be used with
o Contractors MUST have DIC ANZ
authorisation prior to operating a
company forklift truck or attachment.
 To obtain authorisation,
o They must have completed a site
induction

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o The contractor must provide a copy of
their forklift license
o Agree to abide to all DIC ANZ site
regulations
o Sign a copy of this policy handbook
o Sign a copy of the forklift policy

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15 Forklift Checklist

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16 Electric Work Platforms

 These units are the safest means to elevate

personnel especially handy when doing
maintenance.
 All users of EWP’s must be licensed
o Please note that scissor lifts do not require
licences however the user must have been
trained in the safe use.
 All users must have approval to operate on
DIC Australia sites.
 Harnesses must be worn by operators.
o All harnesses must be compliant to AS 1891
o Please note that Scissor lifts may not require
the use of a harness, please check the
operator manual
 DIC ANZ checklists must be completed prior
to use.

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  No operator is to use the elevated work
platform as a lifting device or crane
 Any welding items / power tools / hand tools
must be stored in a tool box, not loose on
the floor of the EWP unit. The floor MUST be
clean and free of any items e.g. Electrical
wires, fittings, rivets anything that may be a
hazard or cause the floor to be slippery.

16.1 Legal issues

 All manufactured overseas units must carry
manuals, written in English, for operator use
in DIC ANZ.
 ALL mandatory issues outlined in the
manufacturers manuals apply for use at DIC
ANZ sites (Operators should read the
manual).

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16.2 Main General Rules to Apply
 Always conduct pre/after start checks, prior
to use.
 Make sure unit is charged prior to use.
 Make sure unit is used only in appropriate
locations on site.
 Make sure unit is only used by operators who
are trained in the safe use
o Have completed the JSA/SWMS for the
activity being undertaken
o Wearing the correct PPE
 Only elevate on flat ground, or place wheels
on blocks.
o These units generally have a self-levelling
ability and will stop operating above 1
metre if the ground is uneven.
 As a precaution using ground controls the
operating cage should be raised prior to an
operator getting aboard at set up point.
 If an operator needs to look under the
platform i.e. to observe level bubble or to
clear or inspect the base of the unit, put the
drop legs in place first to hold up the
platform.
 Never operate in high wind.

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 Never run over open drains, potholes,
electrical wires.
 Never drive across inclines or speed humps.
 An EWP may be designed to be carried on
forklift tines.
o This must be done carefully
o This must be done with a guide walking
in front of the unit to clear a path and to
identify any hazards at all in the path of
travel.
 Never use EWP in wet weather.
 Never climb out of platform while it’s
elevated
 Never disconnect lanyard connecting
operators harness to EWP.
 Always place adequate signage/barricades or
guides around machine while platform is
elevated so vehicles do not run into the
Elevated Work Platform.

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