Forklift University

1 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 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 for powered industrial trucks (forklifts).

2 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. 2 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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.

3 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.

4 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. 3 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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.

5 He tried to duck out of the way, but was unsuccessful; his head was crushed between the mast and cage. 4 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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.

6 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.

7 The doctor told me it was just muscular and that I. was very lucky. He sent me home with Percocet, ibuprofen and muscle relaxers. 5 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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.

8 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. 6 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide OSHA Requirements 7 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 8 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 9 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 10 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 11 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide For the complete OSHA guidelines on Forklift safety you can go to or 12 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide Chapter 2.

9 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. 13 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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 .

10 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. _____. _____. 14 Copyright 2005 - 2010 Forklift University Forklift University Forklift Operator Training Guide 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.