SAFE OPERATION OF FORKLIFT TRUCKS (Distant Learning Version) MATERIALS HANDLING AND LOGISTICS By Brad Porcellato. Contact Porcellato Engineering at 604.526.7964 for payment processing instructions. Certificates and Wallet Cards won't be issued to non-accounts without payment in full!
Safe Operation of Materials Handling and Logistics TABLE OF CONTENTS 1 General Safety Rules 2 Operator's Daily Check 3 The Professional Operator 4 Maintaining Control 5 Maintaining Stability 6 Load Handling 7 Loading & Unloading 8 Batteries 9 Safe Handling of Propane (LPG) Fuel 10 Maintenance 11 Fork Safety 12 Ergonomics 13 Common Factors in Forklift Hazards
Page 1 General Safety Rules are to be operated by experienced workers who are trained, certified or licenced as professional operators. INSPECT forklift daily. Refer to page two of this training manual. Report all malfunctions to the designated authority. Do not operate an unsafe forklift. REPORT accidents / incidents promptly to your supervisor so they can be investigated immediately. DO NOT PERMIT riders on any forklift. ENSURE that battery retainers, fuel tanks and gas caps are secure before starting or moving forklift. DO NOT DRIVE with arms, head or legs outside the confines of the forklift. Check operating clearance space. WATCH for overhead obstructions at all times, especially when stacking or removing material. DO NOT MAKE quick starts, jerky stops, or quick turns, particularly when stacking. ALLOW three vehicle lengths between forklifts. (Tip of fork to forklift ahead) SOUND horn and slow down when approaching pedestrians, doorways, cross aisles, ramps and other forklifts. OBSERVE and obey the load capacity of the forklift. SOUND the horn before moving the forklift when other vehicles or workers may not be able to see forklift movement. PLACE forks as far under the load as possible. Drive with the load against the backrest with mast tilted back. Be sure that the forks are spaced correctly to support load. DO NOT MOVE loads which are poorly piled or stacked. CARRY the load as low as possible. MATCH your speed to the surface being driven on, load and workplace conditions. Be careful when backing up. TRAVEL in reverse when the load is blocking frontal vision. INSTALL mirrors and / or stop signs at hazardous doorways, passageways and work areas. MARK driving and work areas with yellow lines. WATCH out for pedestrians. Avoid driving a forklift up to anyone who is standing in front of a bench or any other fixed object. REDUCE speed when vision is restricted by doors, corners and elevations. Keep to the right unless plant or conditions or layout dictate otherwise. DO NOT PASS a forklift travelling in the same direction at intersections, blind spots, or other dangerous locations. DO NOT RUN over loose objects. KNOW the forklift wheel position in relation to loading docks, trucks, box cars, and or platforms. DO NOT HANDLE the steering wheel if your hands or gloves are greasy or slippery. PARK forklift with controls in neutral, parking brake on and forks in the lowered position. (Motor switch off.) DO NOT ALLOW anyone to walk or stand under elevated forks. DO NOT ELEVATE anyone on forks unless in approved man cage that is secured to forklift truck.
Page 2 Make a daily visual and operational check. WALK around the forklift completely, checking for obstructions. INSPECT the general condition and cleanliness before getting on the forklift. Operator's Daily Check As you walk around the forklift, check for: OBJECTS on the floor that could cause an accident. OVERHEAD obstructions. NEARBY objects to avoid as you drive away. Visual pre-start up check. FIRE extinguisher-present and charged. Operational pre-use check. Test operate all moving parts. LPG, GAS and DIESEL engine oil level. fuel level. radiator water level. ELECTRIC electrolyte level. battery plug connections. FOOT BRAKE pedal holds, unit stops smoothly. PARKING BRAKE should hold against slight acceleration. EVIDENCE of any damage: missing or loose bolts, nuts, guards, chains or hose reels. WHEELS / TIRES condition. FORKS positioning latches and carriage teeth in working condition. CHAIN ANCHOR PINS worn, loose or bent. FLUID LEAKS damp spots or drips. LIGHTS head and warning. (If applicable) HOSES held securely, not loose or rubbing. BATTERY cables and water levels. (If Authorized) DEADMAN SEAT BRAKE should hold when operator rises from seat. CLUTCH AND GEARSHIFT smooth shifting no jumping or jerking. DASH CONTROL PANEL all lights, gauges and horn operational STEERING smooth movement. LIFT AND TILT mechanisms operate smoothly throughout cylinder stroke length. LEAKS no external or internal leaks at lift and tilt cylinders. (Cylinders hold load). Also, no leaking hydraulic hoses.
Page 3 DO's The Professional Operator OPERATE only forklifts that you are skilled licensed or authorized to operate. KNOW the recommended load limit of the forklift and never exceed it. KNOW how to assess the weight of load you are required to lift. PERFORM a visual and operational check at the start of the shift. KNOW that overloading the forklift can cause a lack of steering. CHECK for adequate overhead clearance before raising the load. OPERATE a forklift smoothly when stopping, starting, lifting and tilting. PREPARE for the unexpected and check: -Hands, operators should wear gloves when moving or shifting loads or checking skids. -Boots, operators should wear fully laced safety boots to give impact protection when moving loads or skids and laced to give necessary ankle support when mounting and dismounting forklift. -Fork lift -Load -Route WHENEVER anything develops that affects the normal operation of the forklift: -Make a note of it on the pre use checklist. -Tell your supervisor immediately. DO NOT's KEEP pedestrians away and raise and lower the load smoothly. Any elevated load is hazardous. STAY in the truck in the event of an overturn. KEEP hands, arms, head, feet and legs inside the confines of a moving forklift. REPORT immediately any collisions, damage or nearmiss accidents to a supervisor. STOP when a group of people is walking across the route being travelled: lower the load to the floor and wait until the route is clear, then proceed. OPERATE in a congested area only as fast as conditions safely permit. STAY constantly alert to changing or unusual conditions. DO NOT TRY to move or adjust any part of the load, the forklift or the surroundings when on the forklift. DO NOT LIFT a load that extends above the load backrest unless no part of the load can possibly slide back against the operator. DO NOT ALLOW anyone but the operator to ride on the forklift. DO NOT USE pallets elevated by forklifts as an improvised working platform. DO NOT PERMIT anyone to stand or walk under the elevated part of any forklift, whether loaded or unloaded.
Page 4 Maintaining Control INSERTING FORKS INTO PALLET ENSURE the forks are: -Level. -High enough to go into the pallet. -As wide apart as possible. -All the way under the load. LIFTING, TILTING, STACKING A LOAD. LIFT the load straight up until it is clear, then tilt back. WATCH that the load does not catch on adjacent loads or obstructions. DO NOT RAISE or lower the forks unless the forklift is stopped and braked. ENSURE the forks are free of the load before you back up. TRAVELLING TILT the load backwards DRIVING IN REVERSE FACE to the rear. SOUND horn before moving PROCEED slowly STOP where vision is limited or blocked: sound the horn and proceed slowly. TRAVELLING UP OR DOWNHILL KEEP the forks pointed downhill without a load. KEEP the forks pointed uphill with a load. DO NOT TURN until you are on level ground. DANGERS ON ROUTE BE alert for the following dangers on the floor or roadway: -Oil spots -Wet spots -Loose objects or holes -Rough surfaces -People -Other vehicles TRAVEL with the forks 15-20cm from the floor and tilted back. APPROACH at an angle when crossing railway tracks. MAINTAIN a safe working limit from all overhead power lines. MATCH speed to driving conditions, load and workplace conditions OBEY posted traffic signs.. DECREASE SPEED at all corners, sound horn and watch the swing of both the rear of the forklift and the load. WATCH for pedestrians PARKING Every time you leave the forklift unattended, secure it. PARK in an approved location. SET the brakes. LOWER the forks to the floor. NEUTRALIZE the controls. TURN off the motor switch. DISCONECT the battery or go through propane shut down procedures. SAFE LOADS AVOID sudden stops. DO NOT HANDLE unstable loads.
Page 5 Maintaining Stability LOAD LIMIT ELEVATING THE LOAD DO NOT EXCEED the recommended load limit of your forklift. Each forklift has a maximum load limit. The maximum load limit is shown on the data plate of the lift truck. When the load is raised, the forklift is less stable. When raising a load: DO NOT RAISE or lower the forks unless the forklift is stopped and braked. LIFT the load straight up or tilted slightly back. DO NOT LIFT a load that extends above the load backrest unless no part of the load can possibly slide back toward the operator. STEERING LOAD CENTRE A forklift is designed on the principle of a teeter-totter. POSITION load according the recommended load centre. The load limit of the forklift decreases as the load centre is increased. The weight of the load is carried by the front wheels: Turning is done by the rear wheels. DO NOT TURN a forklift sharply at fast speeds. DO NOT OVERLOAD a forklift. It can cause a loss of steering control. DO NOT ADD extra weight to counterbalance an overload. INSERT the forks all the way under the load. KEEP the load close to the front wheels to keep the forklift stable. CHECK for adequate overhead clearance before raising load. DO NOT ADD extra weight to counterweight to improve steering. MOVING A LOAD KEEP the forks 15-20cm of the ground. ENSURE vision is not blocked by the load. DRIVE slowly. AVOID sudden stops.
Page 6 Load Handling CHECK THE LOAD -Is it stacked correctly and securely? -Is the pallet in good condition? -Is the load within the recommended load limit of the forklift? ENSURE that the mast of the forklift is in an upright position before inserting the forks into the pallet. ENSURE that forks are adjusted for the most spread possible to fit the load. ENSURE that the load is secured before moving: If not re-pile or strap load to skid. SPACE forks as widely as possible to provide more even distribution of weight. ENSURE that palletized loads are stable, neat, crosstied if possible and evenly distributed. SPACE forks evenly from the centre of the pallet (centre stringer) to balance the load. REMOVE damaged pallets from service. CHECK the route you are going to travel before moving load. Look For: -Overhead and doorway clearances. -Dock plates secure. -Weight capacity on floors and dock plates. ENSURE forks are level before inserting them into the pallet. ENSURE forks do not protrude past the back of the pallet when stacking in tight areas. -Proper lighting. -Floor in good condition. -Obstructions.
Page 7 Loading and Unloading Vehicles Vehicles include straight trucks, tractor trailers, railway cars and elevators. ENSURE that the vehicle's brakes are set and it's wheels are properly chocked (blocked). INSTALL fixed jacks to support a semi-trailer to prevent upending of trailer not coupled to a tractor. POST signs not to move vehicle. CHECK that the height of the entrance door of the vehicle is adequate to clear forklift height by at least 5 centimeters. DOCKS AND DOCK PLATES ENSURE that dock plate is properly secured before driving over. Drive carefully and slowly over the plate. Do not spin wheels. Make sure that the plate will carry the load. (Load weight should be clearly marked). INSTALL anti-slipping material in any area that could be a hazard because of weather conditions. ENSURE that docks and dock plates are clear of obstructions and not oily or wet. CHECK the floors to see they will support the combined weight of the forklift and the load. RAILWAY CARS CROSS railway track on a diagonal BACK down and Drive up hills when loaded. SET handbrakes, wheel blocks and derailer before entering railway car. DO NOT PARK forklift within three metres of railway tracks. STAY clear of edges of docks, rail cars or ramps. Edges should be clearly marked. DO NOT TOW or push railway cars or trucks with a forklift. DO NOT LEAVE forklifts running inside vehicle for long periods of time without ventilation. INSPECT interior condition of vehicle: -Trash, loose objects and obstructions. -Check for holes or weak floors. -Ensure proper lighting. -Check for overhead clearance. DO NOT OPEN railway car doors with forklift forks. ELEVATORS DO NOT ENTER any elevator unless specifically authorized to do so. Before entering any elevator, ensure that the forklift plus the load weight does not exceed the elevator capacity. Approach the elevator slowly, stop at a safe distance from the elevator gate and enter squarely. NEUTRALIZE the forklift controls, shut off motor, and apply the brakes on the elevator.
Page 8 Batteries SAFETY PRECAUTIONS Batteries contain sulphuric acid and should be handled by trained and authorized personnel. They produce explosive mixtures of hydrogen and oxygen gases and should be charged in approved battery charging areas. INSTALL a safety shower and an eye wash in battery charging area. WHEN HANDLING BATTERY ACID WEAR splash proof goggles and protective clothing. POUR the concentrated acid into water, not the water into acid. Use non-metallic containers and funnels. USE an eyewash station if electrolyte is splashed into the eyes. Force the eye open and flood with cool, clean water for about fifteen minutes. USE extreme care to avoid spilling or splashing electrolyte (dilute sulfuric acid). It can destroy clothing and burn the eyes and skin. NEUTRALIZE spilled or splashed electrolyte with a baking soda solution, then rinse with clean water. DO NOT STORE acid in hot locations or in direct sunlight. DANGER OF EXPLODING BATTERIES CHARGING BATTERIES UNPLUG or turn the charger off before attaching or removing the clamp connections. Carefully attach the clamps to the battery in proper polarity (red to positive and black to negative). VENTILATE in the space where batteries are charged. SERVICING BATTERIES INSPECT for defective cables, loose connections, corrosion, cracked cases and covers, loose hold-downs and deformed or loose terminal posts. REPLACE worn or unserviceable parts. TIGHTEN cable clamp nuts with the proper size wrench. Avoid subjecting battery terminals to excessive twisting forces. USE cable puller to remove a cable clamp from the battery terminal. REMOVE corrosion on the terminal posts, hold-down tray and hold-down parts. USE a tapered brush to clean battery terminals and the cable clamps. CLEAN dirt from the battery with a cloth wetted with a baking soda solution. Batteries generate explosive gases. KEEP sparks, flames, burning cigarettes, and other ignition sources away at all times. SHIELD eyes when working near batteries. Hydrogen and oxygen gases are produced during normal battery operation. These gases escape through the battery vents and may form an explosive atmosphere around the battery if ventilation is poor. USE a battery carrier to lift a battery or place hands at opposite corners. USE a self leveling filler which automatically fills the battery to a predetermined level. Battery cells should never be filled above the level indicator. DO NOT SQUEEZE the syringe so hard that the water splashes acid from the cell opening.
Page 9 Safe Handling of Propane (LPG) Fuel DO's POSITION the tank so liquid does not come in contact with the relief valve. DO NOT's DO NOT USE metal tools when changing cylinders. DO NOT LET cylinder get to hot. DO NOT MOUNT more than two (LPG) cylinders on any forklift truck. CHECK to see locking pin engages into cylinder. STORE cylinders outside, in an upright position in an area where they can be secured and protected from being struck. Remember valve should be closed tightly. PUT cylinder down gently. Do not drop. CHANGING FUEL TANKS Procedure for changing propane (LPG) cylinders: 1. Wear eye protection and leather gloves. 2. Close valve on cylinder. 3. Run engine until it stops. This ensures that the supply hose is empty. ALWAYS protect valve AVOID contact with propane. Rapid vaporization can cause frostbite. WEAR protective gloves while making or breaking connections. USE only components approved by the Canadian Gas Association (CGA), Canadian Standards Association (CSA), Canadian Transport Commission (CTC), Underwriters Laboratories Inc. (UL) or Underwriters Laboratories Canada (ULC). ENSURE that repairs to the carburetor or fuel supply system are done by a qualified (LPG) service person. EXCHANGE removable cylinders outdoors or in well ventilated areas, away from sources of ignition. CLOSE valve before breaking connections. 4. Shut off engine. 5. Open connecting nut (inspect valves for leaking). Do not use metal tools. 6. Disconnect hose. 7. Disconnect holding straps. 8. Remove empty cylinder. 9. Replace with full cylinder in proper position. 10. Connect holding straps. 11. Tighten connecting nut, (wiggle hose). 12. Open valve on cylinder slowly. Check for leaks. Use soap and water solution. Smell - Listen - Look. 13. If no leaks are found, start motor and resume operation. If leaks are present repeat installation procedure. If leaks continue, have unit repaired by authorized (LPG) service personnel.
Page 10 Maintenance DO's PERMIT only qualified persons to service and maintain equipment. DISCONNECT all batteries and propane before any work is done. KEEP work area clean, and well lit. CLEAN spilled oil or hydraulic fluid immediately. WEAR proper personal protective equipment. Wear goggles when grinding. Wear face shields, aprons and rubber boots when working around battery charging equipment. Wear gloves when changing (LPG) fuel tanks. BLOCK forklift securely when removing wheels. DO NOT's DO NOT LEAVE parts, creepers, cans, tools or other obstacles around. DO NOT LIFT beyond your capacity. Use hoist or leverage tools to lift or move heavy parts or equipment. DO NOT SMOKE, weld or light a match around refueling or battery charging areas. DO NOT START a forklift while on a hoist or wheel stands. DO NOT WORK on forklift attachments unless familiar with their operation. ENSURE all tools and parts are removed before starting engine. SUPPORT forklift hood in upright position or remove when required to do work. HANDLE batteries with care. AVOID contact of battery terminals with hoisting chains, tools or metal objects. DO NOT WORK beneath an elevated forklift or forks unless they are securely supported by an approved hoist or jack. COVER battery top with some insulating material. CHECK bolts that hold counterweight to the frame and replace worn or missing bolts. DO NOT RUN (LPG), Gas or Diesel forklift in unventilated areas. INSPECT forks for distorted, twisted, worn or bent sections. CHECK operator's daily checklist and have repairs made as required.
Page 11 Fork Safety FORK INSPECTION SCHEDULE Under normal operating conditions, forks should be inspected daily and every six months. DAILY: SIX MONTHS: CHECKLIST DO's A visual inspection of forks (by operator) is done on the pre-start up check, with special attention to cracks and deformation. A thorough inspection of forks is done looking for cracks wear and deformation. This inspection may be required more often depending on the use of the equipment. Standard Tire CHECK fork blades for wear. Forks are constantly subjected to abrasion, by concrete floors, steel shelving, etc. This abrasion can reduce the thickness of a fork until it is not capable of lifting to design capacity. CHECK for distortion. Forks can be bent out of shape. Depending on the degree of distortion some forks can be straightened. Contact your forklift supplier regarding fork repairs. Coil Ram Plywood Half CHECK for cracks in heel and hanger. Cracks may appear in forks where (a) attachments are welded or (b) in the inside radius of the bend area. Cracks can be discovered by periodic inspection using the dye penetrant or magnetic particle methods of testing. Some of these blemishes may be ground out and polished by approved grinding methods, depending on the depth of the crack. Contact your forklift supplier. REPLACE with quality forks. When you order forks, make sure your getting high quality forks that will perform you lifting jobs in a safe and dependable manner. Insist on forks that are forged. USE the proper forks. Custom designed forks are needed for: -unusual lifting conditions -spark free areas Contact your forklift supplier for assistance. DO NOT's Carpet DO NOT OVERLOAD. Operators should be aware of the capacity of the forklift, as well as the capacity of the forks. Overloading may bend and weaken forks. FORK REPAIRS AND MODIFICATIONS should be carried out by your forklift supplier or the fork manufacturer.
Page 12 Ergonomics VEHICLE CAPABILITY Is the forklift capable of handling the required lift and load size? Is the forklift designed to operate in the assigned area of operation? Is the forklift stable in all lift and operating positions? Is the load capacity clearly marked on the forklift? Will the floors support the weight of the loaded forklift? Can the forklift make the necessary turns within its area of operation? SEATING Is the seat provided with a shock-absorbing system? Does the seat upholstery resist wear and provide ventilation and thermal insulation? Does the seat have a back rest with lower back support? Is the front edge of the seat rounded? Is there sufficient width and overhead clearance for the forklift to clear structures and walkways? Does the forklift have the required height and or reach to place the load? OPERATOR VISIBILITY Does the operator have a good view: -upward -of the ground (i.e. a squatting person at 5 metres) -in directions of work without assuming a twisted position. LIGHTING Is the lighting sufficient in all directions of travel and work? SAFETY CONSIDERATIONS Make sure the forklift is equipped with these safety devices: -Back-up alarm. -Rear view mirror. -High visibility colour. Back of forklift striped with reflective tape. -Fire extinguisher. -Adequate and readily accessible emergency shutdown. (Dead man seat). -Roll over protection and seat belts. -Air, hydraulic and fuel lines protected from heat and abrasive objects. -Guarding or shielding of exhaust stack, service platform etc. -Special tires (comfort, traction). Is the engine compartment lighting adequate for ease and safety of inspection? Is the forklift lighting adequate (signal, brake and parking lights: headlights, revolving roof light?) As well as acceptable lighting to and from forklift cab.
Page 13 Common factors in forklift hazards The following factors can contribute to forklift truck accidents. Systems - Features of forklift operations -Lack or improper training of workers for those portions of their jobs that involve interaction with forklift trucks. -Production factors - speed, stress. -Lack of availability of tools and attachments and accessories. -Improper assignment of forklifts and operators. -Poor maintenance of forklifts. -Age of forklifts. Behavioural / operational factors -Improper backing up. -Improper turning. -Improper warnings to others of forklift presence. -Requesting / giving rides on the forklift or load. -Walking and working in the general area of forklift operations. Observable characteristics of the workplace -Narrow aisles. -Crowded, cluttered aisles. -Intersections and doors. -Concentrations of traffic. -Condition of the driving surface. -Other conditions - noise, odours, toxic gases, dust, lighting. -Many ramps, different surfaces. -Condition of loading dock. Characteristics of the load -Poor palletizing. -Pallets in poor repair. -Load too heavy. -Load unstable or blocking vision. Features of the lift trucks -Malfunction of brakes. -Poor communication during shared tasks, or in shared spaces. -Parking the forklift. -Improper blocking of wheels on semi-trailers and railway cars. -Non-acceptable behaviours, horseplay, show off driving, jerky driving. -Inadequate servicing of the forklift. -Malfunction of steering. -Malfunction of clutch, shift linkage, or transmission. -Leaks in the hydraulic systems and/or transmission. -Safety devices lacking or malfunctioning. -Emissions from forklifts -Obstructions of driver vision.
Mail or Scan Porcellato Engineering 51058 Crest Centre RPO, Burnaby, BC V3N 5B9 & Email to... Contact: Brad Porcellato, 604.526.7964 Email: brad@porcellato.com First Name Last Name Date Company Address City Postal Code Phone Email We ask for your email to remind you when your certificate and wallet card are close to the expiry date. (Bi-annual contact) OFFICE USE ONLY Test Score Pass/Fail Comments. (Please circle the appropriate answer) Page 1 Safe Operation of Materials Handling & Logistics Final Examination 1. Forklift trucks are to be operated by experienced workers who are trained, certified or licenced as professional operators. True or False 2. Inspect forklift daily. Report all malfunctions to the designated authority. Do not operate an unsafe forklift. True or False 3. Riders are permitted on any forklift. True or False 4. Travel in forward when the load is blocking frontal vision. True or False 5. Watch for overhead obstructions especially when stacking or removing material. True or False 6. Pay attention to pedestrians, they have the right of way. True or False 7. Park a forklift with the controls in neutral, parking brake on and forks in the lowered position. (Motor switch off). True or False 8. It's acceptable for persons to stand under elevated forks. True or False 9. Place the forks as far under the load as possible. Drive with the load against the backrest with the mast tilted back. Be sure that the forks are spaced correctly to support the load. True or False
Page 2 10. Describe the difference between the "visual pre-start up check" & the "operational pre-use check". 11. When inserting forks into a pallet ensure that the forks are level, as wide apart as possible and all the way under the load. True or False 12. When travelling on level ground raise the forks 15-20cm from the floor and tilt the load backwards so it rests against the load backrest. True or False 13. You can handle unstable loads as long as you drive slowly. True or False 14. Keep the forks pointed downhill without a load. True or False 15. Keep the forks pointed uphill with a load. True or False 16. Do not turn until you are on level ground. True or False 17. When driving in reverse, drive as fast as you can. True or False 18. When parking a forklift there is no need to secure it with the parking brake due to the fact that it is very heavy. True or False 19. Match speed to load and workplace conditions. True or False 20. Do not exceed the recommended load limit of your forklift. True or False 21. Add as much weight as you want to counter-balance an overload. True or False 22. Raise and lower the forks at any time when the forklift is moving. True or False 23. Overloading can cause a loss of steering control. True or False 24. Do not lift a load that extends above the height of the load backrest unless no part of the load can slide back toward the operator. True or False
Page 3 25. When loading and unloading ensure the vehicle's brakes are set and it's wheels are chocked. True or False 26. Back down and drive up hills when loaded. True or False 27. It's okay to tow or push rail cars with a forklift. True or False 28. Do not enter any elevator unless authorized to do so. True or False 29. Check that the height of all entrance doors are adequate to clear the height of the vehicle by at least 5 centimeters. True or False 30. Ensure that dock plates are secure before driving on them. True or False 31. Do not park a forklift within 3 metres of railway tracks. True or False 32. It's okay to open railway car doors with forklift forks. True or False 33. Set brakes, wheel blocks & de-railer before entering railway car. True or False 34. Cross railway tracks on a diagonal. True or False 35. Forklift batteries contain sulphuric acid and should be handled by trained and authorized personnel. They produce explosive mixtures of hydrogen and oxygen and should be charged in approved battery charging areas. True or False 36. Neutralize spilled or splashed electrolyte with baking soda solution. Then rinse with clean water. True or False 37. Ventilation is not required in the space where batteries are charged. True or False 38. Unplug or turn the charger off before attaching or removing the clamp connections. Carefully attach the clamps to the battery in the proper polarity. (Red to positve, Black to negative). True or False 39. Inspect for defective cables, loose connections, corrosion, cracked cases and covers, loose hold downs and deformed or loose terminal posts. True or False 40. Use a self leveling filler which automatically fills the battery to a predetermined level. Battery cells should never be filled above the level indicator. True or False
Page 4 41. Position propane tank so liquid will come in contact with the relief valve. True or False 42. Avoid contact with propane. Rapid vaporization causes frostbite. True or False 43. It's OK to allow propane cylinders to become heated. True or False 44. It's OK to mount more than 2 propane cylinders on a forklift. True or False 45. Exchange removable cylinders outdoors or in a well ventilated area, away from sources of ignition. True or False 46. Wear eye protection & gloves when changing (LPG) cylinders. True or False 47. With cylinder valve closed, run the forklift until it stops. This ensures that the supply hose is empty and it is now safe to change the cylinder. True or False 48. After unscrewing the supply hose nut, inspect the valves for leakage. True or False 49. Once a replacement cylinder is locked into place, screw the supply hose nut on to the cylinder (do not use metal tools to tighten) and check for leaks. True or False 50. If small leaks are found after installation, resume operation. True or False 51. A daily visual inspection of the forks by the operator is not required. True or False 52. If bent or distorted, forks can't be straightened. True or False 53. Forks are constantly subjected to abrasion by concrete floors, steel shelving etc. This abrasion can reduce the thickness of the fork until it is not capable of lifting to design capacity. True or False 54. Custom designed forks are needed for unusual lifting conditions such as those found in spark-free work areas. True or False 55. Make sure the forklift is equipped with these safety devices: back-up alarm, fire extinguisher and rear view mirror. True or False 56. Forklifts should be painted a high visibility colour, with the back of the forklift striped with reflective tape. True or False
Page 5 57. Lack of proper training of workers, for those portions of their jobs that involve interaction with forklifts, can lead to accidents. True or False 58. Production factors such as excessive speed can be dangerous. True or False 59. Behaviours such as horseplay, show-off driving and jerky driving are acceptable in large areas where collisions are not likely. True or False 60. Riders are permitted on the forklift or load. True or False 61. Improper servicing of the forklift can cause accidents. True or False 62. Poor communication during shared tasks can cause accidents. True or False 63. Walking or working in the general area of a forklift is not dangerous. True or False 64. Narrow or cluttered aisles can be a potential cause of accidents. True or False 65. Intersections in shelving units or aisles can be dangerous. True or False 66. Poor palletizing or pallets in poor condition are dangerous. True or False 67. Unstable or loads blocking vision are not generally dangerous. True or False 68. Report mechanical malfunctions as they can be safety issues. True or False 69. Lifting loads above the rated capacity of the forklift is acceptable. True or False 70. Noise, odors, toxic gases, dust and poor lighting are all hazards. True or False 71. Forklift exhaust emissions can be very hazardous in confined areas with poor ventilation such as small warehouses. True or False
Page 6 To ensure compliance with the CSA standard B335-94 (Forklift Operator Training), an assessment by the employer is required to confirm a minimum acceptable level of competence. A demonstration of operator skills and Medical / Physical fitness is required. Please review the following requirements. If it is your opinion after evaluating the operator as per the requirements outlined that they meet the requirements please sign and return this form with the test. Students must meet the minimum standard for medical and physical fitness. Students must also sign this document to indicate their compliance to the minimum standard of medical and physical fitness prior to returning this form. Operation Testing Trainees shall be exposed to a practical operating test to demonstrate their skill and understanding of the safe operation of the forklift truck to which they are assigned. The operational test shall include the following items. 1) Operation of the forklift within safety limits - as defined by the employer and/or the forklift manufacturer. 2) Operating techniques - startup procedures, driving, use of controls, stopping, parking, mounting and dismounting the forklift etc. 3) Basic principles of forklift handling - manoeuvring a loaded/unloaded forklift with forks or attachments in position, forward and in reverse, in a confined area, etc. 4) Basic principles of load handling - insertion and withdrawl of forks and attachments without damaging the load, stacking and destacking etc. 5) Basic principles of loading and unloading - transport vehicles, structures & elevators. Employers Name Signature Medical and Physical Fitness 1) Have vision of not less than 20/40 in the better eye and have good judgement of space including height and distance. If corrective lenses are required to comply with the above, the candidate shall always wear them while operating the forklift. 2) Be able to distinguish colour, if colour differentiation is required on the assigned job. 3) Have the ability to hear warning signals. As in the case of eyesight requirement, if the trainee requires a hearing aid to pass the examination, it shall be worn all the time while operating the forklift. 4) Have full movement of the trunk, neck, upper and lower limbs, and have the strength, endurance, agility, and coordination to meet the demands of the job. Students Name Signature Previous Forklift Experience Years Print Name Signature
OCCUPATIONAL HEALTH & SAFETY NOTICE Re: Compliance to the CSA Standard B335-94 (Forklift Operator Training). Effective April 15, 1998 CSA regulations require that all lift truck operators receive adequate Instruction in the safe use of the equipment. Employers must ensure that each powered industrial truck operator is competent to operate a powered industrial truck safely, as demonstrated by the successful completion of the training and evaluation specified in CSA B335-94. I am pleased to offer the following course outline. A demonstration of operator skill is required as well as successful completion of the exam. Both the exam and evauation form are to be returned to Porcellato Engineering (Scan and email preferred). We will retain the exam and evaluation within the students file. The operational test form is in a pass or fail format, all five maneuvers will have to be passed to be considered competent. The correspondence test is in a true or false format and 65% must be achieved. Correspondence Course & Test Trainees shall read the 20 page booklet titled Industrial Lift Truck Operator Training (Materials Handling and Logistics) as well as answer an open book exam containing over 70 questions covered in the booklet mentioned above. The students will cover the following items while reading the booklet. 1) General safety rules. 2) Operator s daily check. 3) The professional operator. 4) Maintaining control. 5) Maintaining stability. 6) Load handling. 7) Loading & Unloading. 8) Batteries. 9) Safe handling of propane (Lpg) fuel. 10) Maintenance. 11) Fork safety. 12) Ergonomics. 13) Common factors in forklift hazards. Operation Testing (Performed by the employer) Trainees shall be exposed to a practical operating test to demonstrate their skill and understanding of the safe operation of the forklift truck to which they are assigned. The operational test shall include the following items: 1) Operation of the forklift within safety limits - as defined by the manufacturer and/or the employer. 2) Operating techniques - startup procedures, driving, use of controls, stopping, parking, mounting and dismounting the forklift etc. 3) Basic principles of forklift handling - maneuvering a loaded/unloaded forklift with forks or attachments in position, forward and in reverse, in a confined area, etc. 4) Basic principles of load handling - insertion and withdrawal of forks and attachments without damaging the load, stacking and destacking etc. 5) Basic principles of loading and unloading - transport vehicles, structures & elevators. Medical and Physical Fitness 1) Have vision of not less than 20/40 in the better eye and have good judgment of space including height and distance. If corrective lenses are required to comply with the above, the candidate shall always wear them while operating the forklift. 2) Be able to distinguish colour, if colour differentiation is required on the assigned job. 3) Have the ability to hear warning signals. As in case of the eyesight requirement, if the trainee requires a hearing aid to pass theexamination, it shall be worn all the time while operating the forklift. 4) Have full movement of the trunk, neck, upper and lower limbs, and have the strength, endurance, agility, and coordination to meet the demands of the job. The correspondence course outlined above is the most popular way to comply with this CSA regulation. The cost is $89.95 per student, or $60.00 each for five or more students. We do bi-annual recertifications at $40.00. To enroll students in the program simply email over their names and I will deliver the programs the following day (Lower Mainland), or download. Don t hesitate to call if I can be of further assistance. Brad Porcellato