Forklift University...Forklift University Forklift training & certification for companies and individuals Operator Training Safety Manual For the: Stand up: High, Medium and Low ...

Forklift University Forklift training & certification for companies and individuals

Operator Training Safety Manual

For the:

Stand up:

High, Medium and Low Order Picker

OSHA Guidelines Safe Forklift Operations

Operator Site/Equipment Evaluation

Forklift University Forklift Operator Training Guide

www.ForkliftUniversity.com Copyright 2005 - 2010 Forklift University

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Chapter 1

Introduction

. . . . .. . . . . . . . . . . . . . . . . . . . In this Chapter

OSHA Accident Summaries OSHA Guidelines

. . . . .. . . . . . . . . . . . . . . . . . . .

Forklifts have become commonplace in the warehouse, construction, manufacturing, and many other industries from the one man shop to the largest operation. It is all about moving materials, from one place to another quickly and efficiently. However, forklifts can also be a dangerous piece of equipment if it is not handled with care and respect. Because of this OSHA (Occupational Safety & Health Administration) began to require forklift operators to be certified in 1998. The training process is outlined in the OSHA Regulations 1919.178 for powered industrial trucks (forklifts). However; basically anyone that operates a forklift must complete a formal training course as well as receive a practical evaluation on the equipment they will be operating at the site. This manual is for Order Picker forklifts and is a supplement to a standard counterbalanced forklift training course. The associated course satisfies the formal training course portion, but it is only a single part of this requirement. Operators are encouraged to use the information and safety training presented here as well as site specific training and evaluations to ensure a safe and efficient working environment.



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Accident Summaries

Forklift Tip over: While an Employee was operating a forklift, the forklift tipped over while the operator was making a turn at excessive speed. No seat belt was installed and when the employee fell from the seat he was crushed by the rollover bar.

Person Falls while standing on a Pallet: The victim was found pinned between the mast and the frame of the forklift. Prior to the accident the person was raised approximately 6 feet high by the forklift operator while they were standing on a wooden pallet not secured to the frame of the forklift. The operator left the forklift unattended while the person was on the pallet pouring spice into a mixing tank.

Fall from a Forklift Platform (Pallet): The employee was in the process of pulling orders from the top shelf of the storage racks in the warehouse area of the grocery store. He was on the raised forks on a wooden pallet, neither he nor the pallet were secured to the forks. The forklift operator was moving along the aisle next to the racks when he hit something with the tire next to the shelf and the forklift stopped suddenly. The employee on the pallet was standing on the front edge of the pallet facing towards the back of the lift. The sudden stop threw him and he fell to the concrete floor hitting his head. The pallet and most of the products remained on the forklift, but he victim died from head injuries.



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Crushed Skull: The victim was a 40-year-old male forklift truck operator for a food production and distribution company, who worked for the company approximately seven years. The day of the incident he was performing the typical task of moving product to a different row of the warehouse using a forklift truck. During this task, the load of product became caught in the narrow aisles and the victim lowered the load back to the ground. He tilted the must forward and stood between the mast and the cage looking over the load to see the obstacle that was preventing him from placing the product on the shelf. His foot caught the lever, which controlled the mast causing it to tilt back toward the cage. He tried to duck out of the way, but was unsuccessful; his head was crushed between the mast and cage.



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ORDER PICKER ACCIDENT as told by operator: I was on an order-picker, it’s almost like a backwards forklift that you stand on, picking up a pallet underneath another shelf. The pallet I was picking up was on the floor and I was watching the blades go into the pallet because I didn’t want to push it thru to the other side and knock everything over. When I was almost done picking up the pallet I felt the shelf above it hit my back and I immediately started the order picker forward and it still went back a little. My body was still turned a little looking at the pallet as it pushed me up against the steering wheel and across the dashboard and pushed my left ear against the clipboard on the windshield. It seemed like it took forever for it to start going forward and I remember thinking I was dead and who was going to take care of my kids. I closed my eyes and kind of grunted as it continued to push me then all of the sudden it started forward and out. I don’t remember unclipping, but I raised the arm to get off, I remember stumbling and seeing spots blinking all over in front of my eyes. I walked to the break table and sat down. Someone came over and asked what I was doing and I told them I was crushed. They asked me if I was ok and I wiggled my toes and fingers and took a deep breath and said I was alive. Then I started to get really cold and they put me in the office and about 10 minutes later they had someone drive me to the clinic. When I got to the clinic on 38th I told them I was injured at work and they handed me L&I papers and it seemed like I waited forever to get in to see a doctor. I can’t remember what order it was in, but I know I only had an x-ray of my chest because I saw it on the screen when I left the x-ray room. I can remember lying there for what seemed like forever scared to move and really cold. The doctor told me it was just muscular and that I was very lucky. He sent me home with Percocet, ibuprofen and muscle relaxers.



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Work Vehicle Accident: Graham was involved in an accident at work in October 2008. Whilst carrying out his normal duties at work as a warehouseman, he received some instructions to go and collect one of the low level order picker vehicles that was parked in its bay. Graham walked along the aisle to get to the order picker that required unloading, when suddenly one of his work colleagues began operating a low level order picker vehicle on the same aisle. The same work colleague had put some cages on the forks of his vehicle and he was trying to park the vehicle in one of the vacant bays. Unable to park in the first bay he attempted, Graham’s work colleague drove the order picker towards another empty bay, which was opposite where our client was now working. As the work colleague attempted to reverse the vehicle into the empty bay, he collided with Graham, trapping his left knee between the moving order picker vehicle and the stationary vehicle that he was standing next to, waiting to unload. As a result of this accident, Graham suffered soft tissue injury to his left knee, which resulted in several days of swelling and several weeks of severe pain.



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OSHA Requirements



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For the complete OSHA guidelines on forklift safety you can go to

www.ForkliftUniversity.com or www.OSHA.gov.



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Chapter 2

Overviews

. . . . . . . . . . . . . . . . . . . . . . . . . In this Chapter

Company or Site Policies Overview of Equipment Order Picker Differences Introduction to Order Pickers Forklift Data Plate Fall Protection Requirements Maintenance and Inspections

. . . . . . . . . . . . . . . . . . . . . . . . .

Forklift operations require the operator to always be aware of their environment, company rules, and the mechanical state of their machines. When policies and safe procedures are not followed, or equipment is not maintained properly and regularly, accidents happen. This guide is an overview of safe operating procedures, rules and guidelines for forklift operators. In this Chapter we review your company specific policies, and some general information about forklifts.



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Company or Site Policies Many companies have special rules in addition to the OSHA guidelines. It is important to follow these rules as well as the OSHA rules when operating your forklift. You can also find rules and instructions on operating your forklift in the owner’s manual. Operator manuals are mandatory on each forklift. Your first day on the job, you should clarify your company policies with your supervisor. List site or equipment policies below: Equipment / Site Specific Information Exapmple

Capacity Information on the Komatsu MPF 15-2A Capacity

• @ 24” _______ • @ __ _______

Lift Height _______” Facility Specific Safety Rules:

1. _______________________________________ 2. _______________________________________ 3. _______________________________________ 4. _____________________________________________________

_____________________________________________________ 5. _____________________________________________________

_____________________________________________________



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Overview of Equipment Introduction to Order Pickers There are many different brands, makes and models of order picker forklifts, but the most common are Crown, Komatsu, Raymond and Clark to name a few. Typically there are low and high order pickers. The difference is that one raises the operator up while the other is more like a pallet jack and does not raise the operator. High Reach Order Picker Forklifts

An order picker is a type of lift truck that features an elevating platform for the truck’s operator. This platform allows the operator to be raised into the air, which facilitates less-than-unit-load picking or stocking. The operator essentially is lifted or lowered to the height of the pick or stock position with the load in order to get access to the product. The lift

platform doubles as the stocking/picking platform as well as the order picker’s driver cab. The platform itself is integrated with the load carrying unit (forks) and the mast. Often, the cab of an order picker features what is known as a “dead man’s switch.” This safety switch (which can be a pedal or other special safety harness) will prevent the order picker from moving unless activated by the operator. The operation of this switch is designed so that movement of the forklift is not possible while the operator is stocking or picking product.

Low Order Pickers

These units operate similar to a pallet jack and do not raise the operator in the air. The

stability characteristics are similar to standard forklift and have a stability triangle and can tip easily.



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Other types of forklifts you may find at your facility or others include: Sit Down Rider Internal Combustion Engine These are generally counterbalanced forklifts. The definition of counterbalanced is, weight added to the rear of the forklift to offset the weight of the load carried by the forklift. The type of tires can be cushion/solid or pneumatic/air filled. Gasoline, LPG, or diesel engines power these forklifts. This type of forklift is intended for use indoors and outdoors, on smooth floors and improved surfaces. These forklifts are front wheel drive and rear wheel steer. Sit Down Rider Electric These are generally counterbalanced forklifts. The definition of counterbalanced is, weight added to the rear of the forklift to offset the weight of the load carried by the forklift. Because of the extreme weight of industrial batteries, the battery is placed towards the rear of the forklift and used as the counterweight. The types of tires are typically cushion/solid, although some electric forklifts use pneumatic/air filled tires. Battery driven electric motors power these forklifts. These types of forklifts are intended for use predominately indoors and have limited outdoor applications, on smooth floors and improved surfaces. These forklifts are front wheel drive and rear wheel steer. Motorized Hand/Rider Pallet Jacks or Walkie Riders

These pedestrian operated machines offer the option of walk behind or a stand up riding platform for operation. A control arm operates steering, braking, acceleration, lifting and lowering. A battery-powered electric driven

motor operates the drive/steer tire and rotates, via the control arm, allowing for a 90-degree turn in either direction. They are intended for use on smooth, flat floors.



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Walkie Stackers Walkie Stackers operate similar to motorized pallet jacks, with steering, braking, acceleration, being on the control arm. These units have a mast like a forklift with lifting heights as high as 15 feet. Lift and tilt controls are generally located on the body of the unit. These units can be straddle or counterbalance design.

Stand up Counter Balanced Electric These are generally counterbalanced forklifts. The definition of counterbalanced is weight added to the rear of the forklift to offset the weight of the load carried by the forklift. Because of the extreme weight of industrial batteries, the battery is placed towards the rear of the forklift and used as the counterweight. The types of tires are typically cushion/solid, although some electric forklifts use pneumatic/air filled tires. Battery driven electric motors power these forklifts. These types of forklifts are intended for use predominately indoors and have limited outdoor applications, on smooth floors and improved surfaces. These forklifts are front wheel drive and rear wheel steer.



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Order Picker Differences from standard Forklifts Un-like standard sit down forklifts, some rules, principles and practices in an order picker may be different or contrary to the rules in a standard lift. These will be identified in the training manual and should be addressed as differences. Some of these differences are:

• All order picker operators must wear a body belt if they are in an order picker that lifts them off the ground

• Order pickers steer differently and have a different steering control. This means that they can turn even sharper than a standard lift and have a shorter wheelbase.

• Operators are typically lifted in the air with the load • Order pickers do not have a 3-point suspension, but have a 4 point

suspension combined with a pyramid center of gravity • A low-rise order picker has a 3-point suspension and a similar center of

gravity to a standard sit down. • Order pickers are not designed to enter trucks, or drive on rough

surfaces. • Order picker operators typically drive forward even with a tall load

because the load is carried behind the operator. • Hi and Medium order pickers can travel with the load and operator

raised, but they will have speed and turning restrictions. It is still not recommended to turn while the load is raised.

• Many order pickers have a guide wire or rail track that helps them to maintain a straight path.

• Most order pickers are electric powered and utilize the battery as part of the counter balance.



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Tires Cushion and Pneumatic Tires are the most common type of tire used on most forklifts; the cushion tire is made of solid rubber and designed primarily for indoor use on smooth surfaces. The Pneumatic tire is an air filled tire and designed for better traction on outdoor or rough surfaces. There are pneumatic tires that are filled with foam or even solid and designed to resist punctures. When inspecting any tire, check for cracks, deep cuts, punctures and excessive wear. And if it is air filled make sure the pressure is correct to maintain proper stability. You should make sure that no lug nuts are

missing and that the wear is not below the wear indicator for the tire. Unsafe tires are a common reason for preventable forklift accidents.

Order Picker Tires While the tires on a sit down counterbalanced forklift may have one of the tire types above, the order picker will have a cushion drive tire and hard solid caster tires for stability. When you inspect these tires, make sure there are no flat spots, chips or broken areas. If the tires or casters are not in good shape do not use the lift, poor tires lead to unsafe stability. These tires and casters have no shock absorbing qualities and it is important they are in good condition and only used on smooth surfaces.



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Forklift Data Plate The data plate on each forklift contains all the basic capabilities and limitations of that forklift. Review the information found on each of the forklift data plates at your facility. The important parts of the data plate you should make sure you are familiar with on the equipment you are driving are:

The model and serial numbers The type of truck The attachments The capacity rating or total amount this forklift can lift The load center or center of the load The lifting height of the mast The overall forklift weight The battery weight if it is an electric forklift

Of course all forklift manufacturers make their data plates differently. They will all have the same basic information on them. As an operator it is very important to understand all the information given on the data plate. A data plate must have all the proper information listed. It must be legible and not painted over or removed. Note that any attachments or mast change added after the purchase of the forklift are, in fact, listed on the data plate. If your forklift data plate is missing, illegible or does not have the proper information on it, report it to your supervisor immediately.



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Maintenance and Inspections Frequent and thorough inspections will help keep forklifts in safe and efficient operating condition. They will also help prevent breakdowns and costly delays. Operators must carefully inspect any forklift prior to use, and report any unsafe or maintenance issues to a supervisor or maintenance staff. Each type of equipment will have different items to check for the order picker you should review the items below. KEY OFF Procedures

! The vehicle inspection ! Hoist lines, cables, and chains ! Hour meter ! Tires ! Battery cables ! Limiting device

KEY ON Procedures

! Check the battery discharge indicator ! Test the standard equipment

! Safety interlock ! Steering ! Brakes ! Lights ! Horn

! Check the accessories ! Gripper jaws

Work platform

The Inspection Sheet provides a convenient reminder of items that must be checked. It also provides the necessary information for scheduling maintenance. You must not assume everything is okay. You must check the forklift before you operate it and you should mark down any needed work, but Operators are to make no repairs or changes unless authorized!



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Forklift Safety Equipment Overview

The safety equipment on the forklift is designed to protect the operator from danger while performing designated job duties. Some of the equipment also provides warnings to other individuals in the area that there are potential hazards. This equipment is to be checked as a part of the inspection process and must be maintained in good working condition at all times. Occupant Restraints On a standard sit-down forklift the operator is kept in the seat by a seat belt. But on the order picker the operator moves freely on the platform and works at heights above the ground. Because of this, proper fall protection gear is mandatory. As of June of 2004, the use of Body Belts on order pickers is no longer an acceptable form of fall protection. After this time, it is necessary for an operator to use a full body harness when operating an order picker. Personal Protective Equipment OSHA 1910.132 The employer shall assess the workplace to determine if hazards are present, or are likely to be present, which necessitates the use of personal protective equipment. Examples of protective equipment that might be required are safety glasses, respirator, hard hat, etc. (This includes the body harness)



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Horn All forklifts must be equipped with a working horn. The horn is used as a warning device. The operator of a forklift must know where to locate the horn. They must test it to see if it is in good working condition before putting the forklift into operation. Overhead Guard The overhead guard is standard equipment from the manufacturer and must be included on the forklift. The overhead guard is not meant for roll over protection. It is only intended to offer protection from the impact of small packages, boxes, and bagged material representative of the job application. The guard will not withstand the impact of a falling capacity load. Backup Alarm The alarm is designed as a warning signal that the forklift is moving in reverse. This is to alert other forklift drivers as well as pedestrians of a potential hazard. This alarm does not relieve the forklift driver of the responsibility of looking in the direction of travel when backing. If your forklift is equipped with a backup alarm, it must be kept in operable condition. Parking Brake The parking brake is a safety device used to prevent the forklift from moving. It should be used whenever the operator leaves the vehicle. Flashing Lights Flashing lights or strobes are optional equipment on a forklift. They are designed to alert anyone around of the forklift's presence. If the forklift has flashing lights, these must be kept in good working order.



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Chapter 3

Principles

. . . . . . . . . . . . . . . . . . . . . . . . . In this Chapter

Order Picker Controls Safe Operating Rules for Order Pickers Guidance Systems The Stability of a Forklift The Load Center Low Level Order Pickers

. . . . . . . . . . . . . . . . . . . . . . . . .

Knowing the safety principles of a forklift is the best way to stay safe on a forklift. While rules and maintenance are important parts of safe operations the principles are something even experienced operators may not understand. This chapter will discuss the safety principles and some safety rules that all operators should know and understand before they operate a forklift.



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Controls Every forklift manufacturer designs their order pickers and reach forklift controls a little differently. There may be more or less buttons, or the action may be different, but the concept and the basics are going to be very similar. There will be a steering wheel usually to the driver side left, there will be a dead man switch on the floor, there will be a right hand level that controls forward and back, raise and lower and any other additional functions the unit has. Operators of order picker units should make sure they are familiar with the specific unit they will be operating and if they have not use this equipment before review the functions in the manual or with an experienced operator. Raymond Controls

Forward/Reverse Lift/Lower

Kill Switch

Steering Control



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Steering Control The steering control turns the drive wheel below the counterbalance. This wheel can pivot in a 360-degree manner. This means that if you are driving forward and turn the wheel 180-degrees, you will go the opposite direction. Do not operate the wheel in such a way as to cause the unit to turn too sharply, this will cause tip over. While it is similar to a steering wheel on a sit down forklift, there is a knob handle to allow the driver to turn the wheel with one hand easily. Since you will more often than not be operating this type of lift facing the wheel, you will be able to turn the wheel to the right to turn right or left to go left. But because there is only a single wheel, like a tricycle, you will have to be careful of the quick maneuverability. Lift Lever The lift lever is a multi-function control that may have thumb controls, or may twist in addition to the other functions. Many manufacturers have a control for forward and back that is similar to a motorcycle throttle, while others have you push the whole arm. There may be additional functions that provide for lift and lower depending on the make and model. Typically this lever is used for controlling the speed and stopping by moving from forward to reverse.

Dead man Switch Foot Peddle

Pallet Lock



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Dead man Switch This control is a foot pedal in the floor of the unit. It is simple to operate, but can be dangerous if you are not familiar with its function. A dead man switch must be depressed for the unit to move. This means that you must be standing on the switch to get the unit to go forward or backward. If you abruptly remove your foot from the pedal, the unit will skid and stop. This is not a good way to stop your unit. When you stop in this manner, you risk the possibility of being thrown from the platform, loosing your load, and also creating a flat spot on the drive tire that will require replacement.

Pallet Locks A pallet lock is located between the forks close to the platform. These must be engaged once you slide the forks into the pallet to make sure the pallet does not slip off the forks while you are loading your cargo. Open the locks before you slide into the pallet and then lock them tight once you have move the forks completely into the pallet. Some units have auto locks and will lock onto the pallet for you. However, you may have to disengage them manually.

Kill Switch A kill switch or stop button is usually red and in a conspicuous location on the main panel of the unit. This button is used as an off button, but can also be use to kill the power to the unit in an emergency. If you are trying to start the unit and it does not start, check both the kill switch (pull it out) and the dead man switch.

Other Controls Depending on the unit, there may be other controls and gauges available to the operator. Some units tell you the height you are at and other functions. Review your operator’s manual for your units’ specific controls.



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Safe Operating Rules Once you are familiar with the controls, you will need to know the proper way to pull product from the racks.

• When utilizing the order picker, you should always stack loads evenly across the pallet and make sure the load is balanced side to side and forward and back.

• Use your legs when placing packages on the pallet just as you would if you were on the ground.

• Be cautious of your footing. If you are stepping on pallets make sure they are strong enough to hold you and your packages and do not step between the boards.

• Never extend or reach outside the running lines of your platform.

• Never climb on to adjacent structures or use the racking as a place to lean or step.



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Guidance Systems Very Narrow Aisle vehicles operate in aisles with little free space between the vehicle and the rack or the overhanging loads. Travel speeds can only be maintained if the operator is free to concentrate on the hydraulic and travel functions. Steering controls within the aisle are part of the "Guidance System". Rail guidance via the vehicle mounted guide rollers and angle iron mounted within the aisle. Wire Guidance requires vehicle electronics and a floor embedded wire to follow. In general there are two types of guidance: Rail Guidance and Wire Guidance both have their benefits.

Rail Guidance As can be seen in the picture, rail guidance is a method in which the vehicle travels between angle iron rails mounted on both sides of the working aisle. A set of four guide rollers mounted on the vehicle maintains the path. The steer wheel is centered electronically in order to prevent oscillation back and forth between the rails; entry guides assist the operator to enter the aisle and optical sensors provide automatic aisle identification - releasing optional travel and hydraulic functions.



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Wire Guidance In the middle of the working aisle a small 1/8" wide x 3/8" deep groove is cut. A flexible and durable wire is embedded in the floor and sealed with epoxy. The wire is installed as a loop with a connection to the LDU "Line Driver Unit" which sends a low voltage RF frequency through this loop. Antenna mounted on the vehicle utilizes this magnetic field and steer the vehicle along its path. Advantages:

• Additional floor clearance without guide rollers - beneficial on uneven floors

• Larger systems tend to be more cost effective with wire guidance - NO additional bottom rack level to compensate for the floor guide rails

• NO mechanical stress on vehicle or floor structures (rails) • Floor level storage without rail interference or structural compensation

(raise floor level or install lower rack shelf level) • Increased flexibility to change the layout - wire can stay in the floor

simply cut new path disconnect area or aisle not to be used • Reduced overall system installation times • Adaptable to full automation



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The Stability of an Order Picker Forklift

A typical narrow aisle reach or order picker forklift has a 4-point suspension system. This forms a stability trapezoid base from the rear drive tires linked to the outside front caster wheels. With the added dimensions of lift and height, it forms a 3 dimensional triangle similar

to a pyramid. This pyramid is from the base of the wheels to the top of the lifting height. Center of Gravity When the combined center of gravity between the load center of gravity and the counterbalance stability stays within the stability pyramid, the truck is stable. If you move the center of gravity forward of the stability pyramid, as when a load is to heavy or to high the truck will tip forward.



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Low Level Order Pickers A low-level order picker is similar to a pallet jack, but because it is motorized you have to use greater precautions and keep your speed slow. When traveling: • Keep your forks 2-3

inches from the floor • Keep the narrow edge of the load up to the heels of the

forks • Travel single file on the left side of the aisle • Keep a safe following

distance, • Do not carry

passengers. • Do not push or pull loads or obstructions aside with

your truck. • Give way to reach trucks and pedestrians

• Use your horn in all blind intersections and doorways

• Make sure you turn corners properly and do not travel to close to racks or buildings.

• Report any damage immediately to your supervisor



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Chapter 4

Safety Guidelines

. . . . . . . . . . . . . . . . . . . . . . . . . In this Chapter

Fueling Overview (Battery Safety) Operator Driving Evaluation Operator Safety Acknowledgement Glossary

. . . . . . . . . . . . . . . . . . . . . . . . .

While operations and the safety knowledge of using a forklift are very important to an operator, the safe charging and physical handling are equally important. Operators should know how to properly charge their units and the next chapter discusses safe procedures for that operation. Operators are required to take a formal safety course, but they also need to have the skills to operate the unit safely. An experienced operator, supervisor or qualified trainer should also evaluate every operator that has completed this course. This evaluation is written and filed with the employees’ files.



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Fueling Overview Special Rules

Follow specific instructions for refueling engines. Refuel only in designated areas or at a remote, fire-safe location. Before refueling, shut engine and lights off. Do not turn them on during refueling.

Smoking is hazardous and prohibited in any area where a forklift is being refueled. Keep the forklifts away from excessive heat.

Refueling should be done well away from welding, open flames and sparks.

If you detect a fuel leak, don't start the forklift. Pull it outdoors. Try to avoid spillage, but if there is any, wash it away.

Wear protective glasses Wear protective gloves Wear other protective gear as required If you are unfamiliar with the proper procedures, stop and get help

Check company administrative procedures for refueling, who does it, when, where, how, etc.



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Battery Charging Only trained personnel are permitted to do this procedure. During charging, batteries give off hydrogen gas, which is hazardous because it is extremely flammable. For this reason, storage of batteries and charging must be done in designated areas away from sparks and open flames. Charging areas should be adequately ventilated and fire protected. Of course, no smoking is allowed in charging areas or when caps are removed to check the electrolyte level or to make a hydrometer test of storage batteries. Battery chargers must be protected from damage by forklifts. Selected personnel should be trained to supervise or handle batteries and to mix electrolyte. Acid should be poured into water. Approved chemical-type goggles or face shield, body shield or apron, and rubber gloves should be worn. An eye wash station should be in the charging area. Trucks shall be properly positioned and brake applied before attempting to change or charge batteries. A conveyor, overhead hoist, or equivalent material handling equipment shall be provided for handling batteries. Batteries shall be properly positioned and secured in forklifts before use. A carboy tilter or siphon shall be provided for handling electrolyte. A supply of fresh water should be available for flushing floors or trucks if electrolyte is accidentally spilled. Vent Caps Vent caps should be checked for proper functioning. The vent caps should be kept in place to avoid electrolyte spray. The battery compartment cover should be left open to dissipate heat. Electrolyte If there is evidence of leaking or spilled electrolyte, it should be flushed away. Report anything that required further action. Electrical Arcing Because of the danger of electrical arcing which can ignite hydrogen gas, tools and other metallic objects must be kept away from and tops of uncovered batteries. Rings, wristwatch or other jewelry must not be worn because accidental contact with electrical parts can cause arcing and severe burns.



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Ten Tips for Safe Battery Handling 1. FOLLOW THE MANUFACTURER'S INSTRUCTIONS Neglecting the manufacturer's maintenance instructions can shorten battery life. 2. INSPECT THE CONNECTORS A loose or pitted connector can cause dangerous arcing or sparking. Don't use the connector as a circuit breaker. Always shut off the charger when connecting or disconnecting the battery. 3. Water Regularly After Charging Add water after charging. Charging increases the electrolyte levels in cells and can cause overflowing if watered before charging. Over flowing means a loss of electrolyte. 4. KEEP IT CLEAN Batteries should be kept clean and dry. If electrolyte is spilled on top of the battery, neutralize it immediately with a solution of baking soda and water. Always wear a facemask or goggles, rubber gloves and a rubber apron when cleaning batteries. 5. DON'T LAY TOOLS ON TOP Battery gases are explosive. Short circuits can cause sparks which may result in an explosion and possible damage to the battery and surrounding area. 6. KEEP VENT CAPS IN PLACE Vent caps allow gases to escape and they keep foreign objects from falling into the cell. Remove vent caps only to add water or to take hydrometer readings. At all other times, keep them securely in place, especially during charging and cleaning. 7. KEEP IT COOL A normal charge can increase the temperature of a battery by 15 degrees or more. Operating hot batteries shortens their overall life, so allow them to cool down before putting back into service 8. DO NOT OVERCHARGE No amount of overcharging will increase battery output beyond its rated capacity. In fact overcharging will substantially reduce battery life. 9. NO SMOKING Always charge batteries in a well-ventilated area. Do not smoke and make sure there are no sparks or open flames in the area. 10. IN CASE OF AN ACCIDENT If electrolyte comes in contact with your eyes or skin,

rinse thoroughly with water for at least 10 minutes and seek medical attention.



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Operator Performance Evaluation

Order Picker

Operator: _____________________________ Date: _____________

Instructor: _______________________ Location: ___________________

Notes: ___________________________________________________________________________________________________________________________________________________________________________________________________

Satisfactory Needs Improvement

Follows Pre-Operation Inspection !Inspect safety harness and lanyard Safe Start Up !Raises forks to correct height !Verifies that the pallet is locked on forks !Checks around lift before moving !Follow additional procedures in operator’s manual Safe Maneuvering !Doesn’t endanger people or property !Stays within safety area when loading product !Avoid jerking controls !Avoid obstacles !Breaks smoothly without skidding !Raise and lower lift smoothly !Follows Guide wire procedures !Turns corners properly !Uses horn when appropriate !Moves slowly when traveling in the raised position !Safe Shut-down !Lowers lift completely before getting off !Stows harness and lanyard properly !Follow additional procedure in operator’s manual



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Operating Manual Acknowledgement Form

By signing this document I am certifying that I have received a copy of the operations manual, OSHA Guidelines and the company policy for the lift similar to the one shown below.

Upon training and authorization by my department, I am expected to operate this lift. I understand that it is my responsibility to review and understand the safe operation of this lift based on the training I receive and the manufacturer’s recommendations.

I understand that if, at any time, I have any questions regarding the information found in the user’s manual I can contact Risk Management and Safety, my supervisor or the manufacturer to obtain my answers.

Name (print) Department User/Operator’s name (sign) Date



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Glossary

Capacity The most weight a forklift can lift to the maximum height if the

mast is in a vertical position. Certification A term that means an operator has successfully completed a

training class and driving evaluation on the equipment they operate for their employer.

Cushion Tires Solid, typically smooth tires used most often in warehouse operations.

Hour Meter The device on a forklift similar to a cars odometer. It measures the time that the machine has been in service.

Load Center The center of the load measured from the face of the forks to the center of the load only. It does not include the forklift body.

OSHA Occupational Safety & Health Administration

OSHA Regulations The rulings and detailed requirements that are to be followed by companies and employees. The specific code for powered industrial trucks (forklifts) is 1910.178. Other regulations cover different industries, machinery procedures etc.

Pneumatic Tires Air, foam or solid tires designed primarily for outdoor use or combination usage. Typically these tires have a tread similar to a car tire.

Train the Trainer This is an instructor training class designed to provide knowledgeable people with the materials, training techniques and guidance to train and certify forklift drivers.

Stability Triangle The 3 point suspension on a sit down forklift.

Stability Pyramid The combination of the 4 point suspension and the height triangle formed in a reach or order picker forklift

Wire Guidance A system that set the forklift to drive in a straight line without operator intervetion

Order Picker A type of forklift designed so the operator pulls the product and loads the pallet at the same time. There are low, medium and high order picker units.

Narrow Aisle An aisle that is less than 10 feet wide, requiring a special type of forklift.

Dead Man Switch A foot pedal that kills the forklift operation when not depressed

Kill Switch The on and off switch, usually a pull put or push in for operations.

Low Level order picker

An order picker that does not raise the operator, but is similar to a motorized pallet jack.



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