2. Personal Protective Equipment (PPE)

Always wear appropriate PPE for the task at hand:

Task-Specific PPE:

• Face Shield: for grinding, cutting, or handling hazardous chemicals
• Chemical-resistant gloves: when handling batteries, hydraulic fluid, or other chemicals
• Hearing protection: when noise levels exceed 85dB
• Respiratory protection: when working with dusty components or chemicals with fumes
• Fall protection: when working at heights above 4 feet/1.2 meters

3. Pre-Service Safety Checks

Before beginning any service work:

Secure the Area:

Forklift Preparation:

Tools and Equipment Check:

4. Lockout/Tagout Procedures

Standard LOTO Procedure:

Required LOTO Equipment:

• Personalized locks with single key
• ID tags with service engineer's name and contact information
• Multiple-lock hasps for group work
• Battery terminal covers
• Hydraulic line caps

5. Working at Heights

Height Safety Requirements:

• Always use appropriate fall protection for work above 4 feet/1.2 meters
• Inspect ladders before each use
• Follow the 3-point contact rule (Two hands and one foot, or two feet and one hand)
• Secure tools to prevent drops
• Never stand on forklift forks to reach heights
• Use properly rated lift platforms or scaffolding when necessary

6. Electric Forklift Battery Safety

Battery Service Requirements:

7. Hydraulic System Safety

When Servicing Hydraulic Systems:

• Relieve pressure before disconnecting lines
• Use cardboard, not hands, to check for leaks
• Properly contain and dispose of hydraulic fluid
• Replace hoses at first sign of wear
• Use proper torque specifications for fittings

8. Tire Handling Safety

Tire Service Requirements:

• Use proper handling equipment
• Verify rim components are compatible before assembly
• Inspect for damage before installation

9. Ergonomics for Service Engineers

Prevent musculoskeletal injuries with proper ergonomic practices:

Lifting and Material Handling:

• Use proper lifting techniques: Bend knees, keep back straight
• Get help for items over 50 lbs / 23kg
• Use material handling equipment when available
• Avoid awkward postures and extended reaches

Work Positioning:

• Take breaks to stretch and change positions
• Adjust work height to avoid bending and reaching
• Use anti-fatigue mats for extended standing

10. Emergency Procedures

Medical Emergency:

• Call emergency services immediately
• Administer first aid if trained
• Do not move injured person unless in immediate danger
• Report incident to supervisor as soon as possible

Fire Emergency:

• Evacuate area if fire cannot be safely controlled
• Use appropriate fire extinguisher (Class ABC for most forklift fires)
• Never use water on electrical or chemical fires
• Follow facility evacuation procedures

Chemical Exposure:

• Rinse affected area with water for at least 15 minutes
• Remove contaminated clothing
• Seek medical attention immediately
• Reference SDS for specific treatment information

11. Safety Documentation

Always have access to these critical documents:

Reporting Incidents and Near Misses

All incidents and near misses must be reported immediately through the appropriate channels. This helps prevent future incidents and maintains a safe work environment for everyone.