Forklift Operator Training Guide 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. 51 www.ForkliftUniversity.com
Forklift Operator Training Guide 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. 52 www.ForkliftUniversity.com
Forklift Operator Training Guide Other Fueling Procedures Gasoline and Diesel Fueling Refueling: Make sure to follow manufacturer's recommendations for refueling the forklift. Gloves, goggles, and a long sleeved shirt are necessary safety precautions when refueling a gasoline or diesel forklift. Fuel tanks should not be filled while the engine is running. Spillage shall be avoided. Fuel or oil spillage shall be carefully washed or wiped away and the fuel tank cap replaced before restarting engine. No forklift shall be operated with a leak in the fuel system until the leak has been corrected. Check the OSHA Act and NFPA Codes No. 30 and No. 58 for more details on fuel handling and storage of gasoline and LPG, if either or both are used. Liquefied Petroleum Gas (LPG) Refueling: Make sure to follow manufacturer's recommendations for refueling the forklift. Gloves, goggles, and a long sleeved shirt are necessary safety precautions when refueling a LPG-type forklift. Make sure that the forklift ignition is off, close the tank shut-off valve and let the engine run until it stalls. Remove empty LPG tank and replace with full LPG tank, checking that the tank fits into the positioning holes. Reinstall hose fittings. Use your eyes, ears, and nose to inspect for leaks. Soapy water sprayed on connections may also be helpful in detecting a leak. No forklift shall be operated with a leak in the fuel system until the leak has been corrected. Be sure to secure tank to forklift. Storage: Store cylinders in a safe and approved method. Check your local regulations and fire codes for the correct procedure. If possible, store forklifts and cylinders under sprinklers for better protection against fire. Check the OSH Act and NFPA Codes No. 30 and No. 58 for more details on fuel handling and storage of gasoline and LPG, if either or both are used. 53 www.ForkliftUniversity.com
Forklift Operator Training Guide Chapter 6 Overview of Site Requirements Overview of Employer Responsibilities Driver Site & Equipment Evaluation Form As we conclude this course it is important for you, the forklift operator, to take personal responsibility for your own safety as well as the safety of those around you. There are some additional requirements when you return to your job site, but you now know the safe procedures, principles and requirement for forklift operations. If at any time you are observed driving unsafely, you have a near miss or accident you are required by OSHA to be re-evaluated and re-trained. Your forklift certification is valid for 3 years from the day you completed the class, if you need to renew your license you can do that at our web site www.ForkliftUniversity.com. 54 www.ForkliftUniversity.com
Forklift Operator Training Guide Overview of Site Requirements Once you have completed this safety course you are considered certified, however, the OSHA requirement is that you not only have to take a formal training class like this one but you must be trained, authorized and evaluated on the specific equipment at the site you will be working. Overview of Employer Responsibilities Your employer should make sure that you and all other forklift operators (that is anyone that gets on a forklift) is trained, authorized and certified. Employers are responsible for providing you with safe equipment to use as well as a safe environment and rules or guidelines in hazardous areas. Staffing Agencies New operators can utilize the job placement services of staffing agencies to break into the field and get entry level jobs that can turn into good paying permanent positions. For those that will be using the services of a staffing agency, you will be required to show your training certification card. They will ask you about your experience, answer these questions honestly and if you are taking a driver training class let them know that as well. Staffing agencies can provide you with forklift jobs, but the company you are working at should still perform an operator driving evaluation and document the equipment they will be authorizing you to operate. Forklift Job Placement Forklift University does not do job placement, this is left to the professionals at the staffing agencies. We do post job openings on our web site for free. If you company or staffing agency wishes to have a job posted please send an email to [email protected] with the job information and we will post the job for you. Individuals can see our staffing partners and job postings on line at any time for no charge. 55 www.ForkliftUniversity.com
Forklift Operator Training Guide Forklift University This manual prepared by Forklift University and should not be reproduced or copied without their express written consent. While this course is only a safety-training course based on the OSHA standards, forklift operators will still need to be observed and certified that they know how to operate the specific equipment at their job site. Forklift University offers additional training courses: • Stand-up and Sit-down Forklift Operations • Company Specific Train the Trainer • Aerial Lift and Fall Prevention Certifications • Renewals and Certifications on line • Train the Trainer Classes For more information call us directly or visit our web site: 888-674-9992 www.ForkliftUniversity.com Copyright 2005-2019 Forklift University Inc. 56 www.ForkliftUniversity.com
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