Made Better In The USA by: Phone: (009) 352-8393 carom 7 ; acs Gaus Saeennours jltronics or (00) seo seae ee at : ee ‘werw mlvones com info@mitenics com Forklift Alert™ Forklift Proximity Pedestrian Notification System Installation and Operation Manual Forklift Alert™ is a proximity warning system for pedestrians. It’s our all new, patent pending solution for improving facility safety and awareness. A transmitter mounted on your forklifis emits a high frequency radio signal that is detected by our receiver to war surrounding pedestrians. The transmitter operates on the forklift power supply and is easily installed by maintenance personnel. ‘The recciver is wall mounted in areas where pedestrian traffic occurs. ‘When the receiver detects forklift activity in the vicinity, audio and visual warning indicators let pedestrians in the area know that an operating forklift is close by. The Receiver does not require line of sight to the forklift mounted Transmitter. The Receiver can be mounted around corners from the moving forklift and it will still receive the incoming transmissions from the forkli ‘The Receiver has an on board audible warning and a case mounted lamp for a visual warning in addition to the two accessory ports for enhanced audio and visual warning devices (sold separately). 95 Krif Road, Keene, NH 03431 Main Office: 603-352-3333, Technical Support: 603-355-6677 Email: [email protected] www forkliftaler.com Made Better In The USA by: Miltronies Manufacturing, Inc. Forkit Alet™ Systems Rev. 2014-12-18 Copyright © 2014 Mitronies Manufacturing, ne Page l of 12Mage Geter In Tha USA by: Phone: (602) 352-2332 Miltonies Manufacturing Ie Sales: (800( 828-9089 Seas iltronics Fan ten nau wu mitrnies.com Infogemionies com Table of Contents: Forklift Alert™ Warranty Statements RF Operation ‘Important Notice ‘System Features ‘System Components Important Notice ‘Transmitter and Flux Capacitor/Power Converter Installation ‘Transmitter and Flux Capacitor/Power Converter Operation Receiver Installation Receiver Operation Receiver Proximity Range Adjustment System DIP Switch Coding System Set-Up Test Figure 1 - Flux Capacitor/Power Converter Placement Diagram Figure 2 - Flux Capacitor/Power Converter Set Up Diagram Figure 3 - Receiver Set Up Diagram Figure 4 - Receiver Alert Timer, Tuning and System Coding Diagram 10 Additional Information from OSHA, ITA and NIOSH u Caution and FCC Statement 12 CeIAAWUNRRwWONN Ny Forkiift Alert Limited Warranty: Miltronics Manufacturing, In. has a one-year warranty on parts and ninety ‘days on labor. Miltonics guarantees all pars ofthis product to the original owner against manufacturing or parts defects. This warranty shall not apply to defects resulting from improper installation or use, unauthorized repair and consequent damage, abuse, modification, using ina fashion other than intended, fie, flood or act of God, or on which serial numbers have been altered, defaced or removed. If your unit cannot be repaired, Miltronics may replace itwith new or reconditioned merchandise. Miltronics will assume no liability for commercial loss or any kind of damage resulting from malfunction of the product, or resulting from its unsuitable use. In any event liability shall ‘ot exceed the original purchase price. Forklift Alert™ Warranty Return and Repair Policy: The entire system requiring warranty repair must be returned to Miltronies, by prepaid freight, with proof of purchase, a brief description of the problem and a daytime phone number to contact you if necessary. A handling fee will apply for products sent to Miltronies that are not ‘covered under warranty. RF OPERATION: All wireless devices are required by the FCC to operate subject to the following two ‘conditions: (1) This device may not cause harmful interference and (2) This device must accept any interference received, including interference that may cause undesired operation. IMPORTANT: READ ENTIRE MANUAL BEFORE INSTALLATION AND OPERATION. ‘THOROUGHLY TEST BEFORE OPERATION. CALL TECH SUPPORT (603-355-6677) WITH ANY ‘QUESTIONS. **Prior to forklift operation, perform the System Set-Up Test (see page 6)** —————— Fork Alert™ Systems Rev 2014-1248 2 of 12 Copyright® 2014 Mtronics Manufacturing, ne aie torMade Better In The USA by: Phone: (603) 352-3333 Mitonies Manufacturing, I 95 Kit Road lt, a, sabe fe 528 2 ote iltronics one oe, unr Forklift Alert™ System Features: Alerts Pedestrians of On-Coming Forklifts Perfect for Blind Intersections ~ Line-of-Sight is Not Required Compatible with All Forklifts (Gas and Electric, 9 Volts to 75 Volts) ‘Two Models Available: 9 Volts to 36 Volts and 18 Volts to 75 Volts Easily Customizable to Customer Specific Requirements Quick and Easy Installation by Maintenance Personnel Industrial Casing Designed to IP65, NEMA Specs and UL Listed Casing has Silicon Rubber Gaskets for Adverse Indoor Conditions Cases Equipped with SS Captive Hardware and Mounting Flanges Casing Made of Flame Retardant ABS Plastic High Quality Stainless Steel Connectors Rated P67 M9 Threaded Locking Connectors with Gold Plated contacts Polarized Connectors to Avoid Misalignment and Incorrect Placement Coded Components for Group Distinction Helps Reduce Risk of Lawsuits and Liabilities Maintain Lower Insurance Costs Helps Reduce Risk of Injury Forklift Alert™ System Components: Standard Items: 1,) Forklift Alert Receiver 2.) Receiver 110-Volt Power Wall Transformer 3.) Forklift Alert™ Flux Capacitor/Power Converter 4.) Power Cable (connects forklift power to Flux Capacitor/Power Converter) 5.) Forklift Alert™ Transmitter 6.) Transmitter Cable (connects Flux Capacitor/Power Converter to Transmitter) 7.) Hook & Loop Fastener (to mount Transmitter to upper forklift rail) 8.) Cable Cleats (to route and secure all cables) 9.) Mounting Hardware (to secure various system components as needed) 10.) Forklift Alert™ Operation and Installation Manual Optional Items: 1.) Receiver Strobe Light and/or Siren (sold separately) 2.) Forklift Strobe Light (sold separately — connects to Flux Capacitor/Power Converter) 3.) Accessory Cable, 10 foot Extension (sold separately — connects accessories) 4.) Extra 5 foot Extension Power and/or Transmitter Cables (sold separately) IMPORTANT: Forklift Alert™ MUST ONLY BE INSTALLED AND SET UP BY AUTHORIZED MAINTENANCE PERSONNEL THAT ARE TRAINED AND. FAMILIAR WITH FORKLIFT OPERATION, MAINTENANCE AND SERVICING. ALWAYS DISCONNECT FORKLIFT POWER PRIOR TO INSTALLING OR SERVICING THE Forklift Alert™ SYSTEM OR ANY OF ITS COMPONENTS. Ss Forksit Aler™ Systems Rev. 2014-12-18 a Copyright © 2014 mitronics Manufacturing, Ine 18Page 3 of 12Mage Betier In The USA by: Phone: (603) 352-2999, Mitzonies Manufacturing, ne ‘Sales: (@00( 828-5089, eo, Ni oo491 jltronic. Ss Fane (ens) asad wav mitvonies.com ‘nfo@tronies com Forklift Alert™ Transmitter and Flux Capacitor/Power Converter Installation: The Transmitter should be mounted on an upper rail of the forklift with the “Arrow” pointing in the direction of travel and the Flux Capacitor/Power Converter should be mounted inside the operator's compartment for easy viewing of the Transmission Verification Diode and easy access to the Lighted Power Switch. See Figure 1 for recommended mounting locations. Using the included hardware or other secure mounting methods, install the Transmitter and Flux Capacitor Power Converter. Under no circumstances should the Transmitter be covered or shrouded. IMPORTANT: The Flux Capacitor/Power Converter comes in two models. There is a 12-volt model for forklifts that operate on 9 to 36 volts and there is an 18-volt version for forklifts that operate on 18 to 75 volts. Ensure you have purchased the correct system. A Test Transformer is provided with your initial system. This allows for a preliminary “cart” test using 110-volt wall transformer for power prior to forklift installation, Ensure the proper voltage for your system is selected on the Test Transformer. Save the Test Transformer for future use. Once the Transmitter and the Flux Capacitor/Power Converter are installed, the Power Cable and ‘Transmitter Cable can be attached. See Figure 2 for a set-up and features diagram. Starting at the Transmitter, carefully connect the Transmitter Cable to the Transmitter and route the cable to the Flux Capacitor/Power Converter. Coil excess cable, connect the other connector to the Flux Capacitor/Power Converter and securely cleat the cable so it is out of the way and will not present a hazard, Next connect the Power Cable starting from the power connection. Refer to your forklift manual for recommended connection methods. Route the cable to the Flux Capacitor/Power Converter. Coil up excess cable, connect the other connector to the Flux Capacitor/Power Converter and securely cleat the cable so itis out of the way and will not present a hazard. Securely tuck away and cleat excess lengths from both cables. Additional 5 foot Extension Transmitter and Power Cables are available. Forklift Alert™ Transmitter and Flux Capacitor/Power Converter Operation: ‘The Flux Capacitor/Power Converter has a lighted On/Off Switeh and a Transmission Verification LED. If power is not present when the switch is turned on, the switch light will not operate. If there isa fault in the system's transmission, the Transmission Verification LED will not be illuminated. If either of these operational lights is not illuminated, DO NOT operate the forklift until the problem is identified and corrected. The Flux Capacitor/Power Converter has a built in accessory port to accept and power an optional enhanced visual or audible accessory (Gold separately) that can be mounted on the forklift for additional safety, IMPORTANT: On systems with multiple forklifts, the “Trigger Point” may vary slightly from forklift to forklift. This is normal and not a problem when the Trigger Point is properly set. If necessary, a slight repositioning of the Transmitter with the furthest Trigger Point may reduce the difference. Also, Transmitters are easily interchangeable, For best results, place the ‘Transmitter with the furthest Trigger Point on the fastest vehicle. — Fork Aler™ Systems Rev. 2014-12-18 aoe Copytignt@ 2014 Mitronies Manufacturing Ine 18Page 4 of LMade Bettor In The USA by: Phone: (603) 362-9333 Mitonies Manufacturing, Inc Seles: (800( 820-9089 eo ie iltronics "alc werw.mitonies.com infogmitronis com Forklift Alert™ Receiver Installation: ‘Choose a suitable location to mount the Receiver where there is an available 110-volt outlet. Connect the 110-volt Wall Transformer connector to the Receiver then plug into a 110-volt outlet. See Figure 3 for a set-up and features diagram, The green power indicator lamp on the Receiver will tum on. Locating the Receiver so it has line-of-sight to the moving forklift is NOT required. The Receiver can be located around the corner from a moving forklift and still receive the forklift's transmission to warn pedestrians as they approach the intersection. DO NOT permanently mount the Receiver until the Forklift Alert™ Transmitter has been installed and proximity range has been verified and adjusted, if necessary. The reception range is adjustable from about 10 feet to about 90 feet depending on your environment. ‘The minimum. recommended range is 35 feet. Due to local environmental issues and the characteristics of RF signals, it may be necessary to slightly alter the initial Receiver location for best operation. Forklift Alert™ Receiver Operation: Verify the Receiver is securely mounted, plugged in and the green power indicator light is illuminated. Press the Test/Reset button to verify the operation of the Red Activity Lamp, the two Red Accessory Lamps, Optional Accessories and the built in audible Alert Tone. As long as the forklift is within the pre-set range of the Receiver, the Receiver warning lamps and warming tone will continue to operate. Optional enhanced andio and visual alert accessories are available for more severe environments where additional visual or audible alerts are requited On the Receiver circuit board, there is an Alert Tone volume control, Event Diode and an on board jumper that is used to set the Alert Time duration (See Figure 4). This is the time that the Receiver continues to activate after the forklift has left the reception. range. The Receiver can be set to alert for $ seconds, 10 seconds or to “Stay On”. To stop the alert signals while in the “Stay On” mode, simply press the reset button. The alert duration factory default is 5 seconds. Forklift Alert™ Receiver Proximity Range Adjustment: Every environment is different and therefore, the exact operation of all RF devices will vary from one environment to another. These environmental differences can be attributed to other RF devices, metals/materials, stray clectronic signals, obstacles (walls, racks, shelving...), ete Miltronics has developed a tuning method to achieve stability within each environment, ‘There is a bank of DIP switches located on the Receiver circuit board that is used as the interface for customer adjustments, See Figure 4. However, one Receiver that is set to a range of 30 feet may behave differently when moved to a different environment. Prior to initial use and when relocating a Receiver, always perform the System Set-Up Test (see page 6) and make any necessary adjustments. For maximum range, place all DIP switches in the down (OFF) position. For minimum range, place all DIP switches in the up (ON) position. In general, the first DIP switch will have the greatest effect and the last DIP switch will have the least effect. Positions 1 through 4 are for coarse adjustment and positions 5 and 6 are for finer adjustment. ‘The factory default is approximately 25 to 35 feet. This will vary depending on your environment. ee Forkat ler Systeme Rev, 2014-12-48, age 5 0 Copyignt © 2014 Mitronies Manufacturing ne ad sellaPhone: (603) 352-5038 Sales: (600{ 828-9089 oon Na OAS iltronics Fon coea-tae ae. oareeea Forklift Alert™ System DIP Switch Coding: All Forklift Alert™ Transmitters and Receivers are compatible. On cach system component's circuit board there is a 5 position DIP Switch used to code Transmitters to Receivers. See Figure 4. This allows for groups of system components to NOT react with or accept signals from other groups of system components that are coded differently. This feature should only be used when there is no possibility that a forklift coded to one group would travel in the area of a differently coded group. Serious injury could result. Forklift Alert™ System Set-Up Test: ‘Completely test your system set-up prior to placing it into use with pedestrians. With the Receiver temporarily located (sce instructions page 4), operate the forklift in all areas it could travel and approach the Receiver from all possible directions. It is recommended that the forklift be traveling at typical speeds and carrying a typical load, While one qualified person operates the forklift, another person must observe the Receiver’s activity, As the forklift approaches, note where the forklift is located when the Receiver is activated. Using the on-board Receiver Proximity Range Adjustment, you can increase or decrease the range as required. Depending on your particular environment and your desired results. It may be necessary to test different Receiver locations for best performance. ‘Test and re-test until the activation range and system operation is satisfactory. Miltronics recommends a minimum activation distance of 30 feet. Use the following table to record range testing results: FIRST RANGE TEST: Direction 1 Distance from Receiver: Direction 2: Distance from Receiver: Direction 3: Distance from Receiver: Direction 4: Distance from Receiver: SECOND RANGE TEST: Direction 1: Distance from Receiver: Note: Direction 2: Distance from Receiver: Note: Direction 3: Distance from Receiver: Note: Direction 4: Distance from Receiver: Note: THIRD RANGE TEST: Direction 1: Distance from Receiver: Note: Direction 2: Distance from Receiver: Note: Direction 3: Distance from Receiver: Note: Direction 4: Distance from Receiver: Note: Additional Notes: —— Fort Alert™ Systems Rov. 2014-12-18 eae Copyright® 2014 Mitronies Manufacturing, Ine 18PagSeles: (600( 828-088 (603) 362-4486 ‘won fokialert.com ‘rteqamtonies, com Fase Phone: 603) 352-3333 iltronics Made Batter In The USA by: Mitonies Manufacturing, ne 95 Kf Roa Keene, NH 03431 wera tones com uowie22|4 Jep|UIsueY pue JeLaAuo> 1oMogjioy>edeD xn|J:t Bun Ly ‘jqe> ss9>x9 Keme yam pue dn N09 yeusnuo> Jemog/ioyrede> Xn}4 2u2 ©) Jojuisueu, aip wo aged Jo RNWSUEN, ‘943 2un2as pue B3N91 LOU YaUBAUOD O2 {Aiddns aM0d wou 21ge9 J9Mod aund9s puE ‘anol 03 sie3}9 ajqe2 payddns asp 220N passeope pue pamain ovo paw6rn ain pue a Uojssiuisueit 24 0s Uo} Uj aed uaWIedWoD sorerado ain aPISUI daylenuio9 Jemog/IoyedeD xn} 943 IUnOW uewo3 ey doy a4 jo doy uo JemWISUEN, 949 JUNO 18Page 7 of 12, Copyright© 2014 Mion Manufacturing, InePhone: (603) 362-3333 (603) 352-4444 ‘wor forklaert.com infogmatronis com Sales: (600{ 826-9089 Fa Guypusg wares sn ayy ut ape ‘Te¥cO HN ‘2uao3,‘peoH ju sé Dur BuUmenueHy S.UO.IIH iltronics YALLIWSNVL wiLdaTY LAT DYOS eee av ge 58 2a si ee 33 yet alee Hat b SuoA29ULIOD qEUOdWOE WAYSAS y.UDIy YIPHOY :Z aunbi 433d § - 37@V9 NALLINSNYUL yeures uid BIeW Ula & ajewed Uld & ‘andano 4a1eAu0D IEW Ud & dup Joqiwusues,, ajewiag uid Z 30 HOA ZT Huog Alossa20y 4334 §- 779 NaMod DMNW OF - led padi r30unOg aMog D104 03 woRSsUU0D, yeh uid € {nding 4amog PHOS J “HOMNO ajewiay ule € SOA SZ - ST SiIOA 9 - 6 1epow Ay, snd JeMog TEPEO HN etn, peau Ju $6 ‘ur ’Buua2enUeH S>}UOLyE YALWBANOD Y3MOd WOLIDWd WO XM YAY LITDOS @ onumsmrn Fern Aer Systoms Rev. 2014-12-48 18Page 8 of 12 Copyright® 2014 mitronies Manufacturing nePhone: (003) 352-9359 ‘Sales (@00( 828-0089 (Gos) 352-4446 ‘wer forkaler om [email protected] Fac prewad uid € ‘20 110N zt sanduy samo aiew uid € Saion zt sanding 43mog iltronics ov aenort ueunojsued, eM af 38 HE: eBeee Hab ‘suoRPOULOD 49N/909y yw HOIY PHOS +E BUNGLE anes BEY IY 5 )°e@ zy ry ‘wSAHORY "peo su $6 ur ‘SuLRDeUeN S1UOI WALSAS ONINYWM ALIWIXOYd wild LITDINOd Li 1 e OO ° arewey uid z Da OA ZT sod Atossso3y Fork Aen Systems Rev. 2014-12-18 18Page 9 of 12 Copytight ©2014 Mitrorics Manutacturing, IneMade Better In The USA by: ame wane weestneee iI ! Sony Gila ree ft ultronics "eevbracin Sakae, infogmironics com ssec oa | ssc | pom a ox | © [2 Bll: Receiver Alert Timer Duration Jumper Settings tGUUGue Maximum Range: All Switches Down (OFF) Minimum Range: All Switches Up (ON) Position 1 - 4: Relative Value Position 5: Relative Valu Position 6: Relative Value 1 iaGbee |\teebee Five Position Reveiver Coding DIP Switel Five Position Transmitter Coding DIP Switch Figure 4:_ Forklift Alert™ Receiver Alert Timer Jumper Settings, Receiver Tuning DIP Switches and System Coding DIP Switches Fork Alen™ systems Rev. 2014-12-48, ae Copytignt ©2014 Matronies Manutzetuing, Ine 18Page 10 of 12Made Better in The USA by: Phone: (603) 252-2333 Mionies Manufacturing, Inc Sales: (600 826-0089 Eee iltronics nae oul come Additional Information from OSHA, ITA and NIOSH: OSHA estimates forklifts cause about 85 fatal accidents per year; 34,900 accidents result in serious injury; and 61,800 are classified as non-serious. According to the Industrial Truck Association, there are about 855,900 forklifts in the U.S. Therefore; over 11% of all forklifts will be involved in some type of accident each year (assuming only one accident per forklift). The ITA also reports that the useful life of a lift truck is about 8 years. This means that about 90% of all forklifts will be involved in some type of accident during their useful life-again assuming only one accident per forklift. If you operate this equipment, there is a possibility that you may have an accident at some point during your career. To help reduce the possibility of being injured, it's important to understand where and how these accidents occur. Source...toolboxtopics.com Reminders for the Pedestrians: Be aware that lift trucks cannot stop suddenly. They are designed to stop slowly to minimize load damage and maintain stability. Stand clear of lift trucks in operation. Avoid a run-in, The driver's visibility may be limited due to blind spots. Be aware of the wide rear swing radius. Use pedestrian walkways, or stay to one side of the equipment aisle. Never ride on a forklift, unless authorized and the forklift is designed for riders, Never pass under an elevated load. ‘Source... OSHA Workers on Foot Separate forklift traffic and other workers where possible. Limit some aisles to workers on foot only or forklifts only. Restrict the use of forklifts near time clocks, break rooms, cafeterias, and main exits, particularly when the flow of workers on foot is at a peak (such as at the end of a shift or during breaks), Install physical barriers where practical to ensure that workstations are isolated from aisles traveled by forklifts. Evaluate intersections and other blind comers to determine whether overhead dome mirrors could improve the visibility of forklift operators or workers on foot. Make every effort to alert workers when a forklift is nearby. Use horns, audible backup alarms, and flashing lights to warn workers and other forklift operators in the area. Flashing lights are especially important in areas where the ambient noise level is high. Source... NIOSH CAUTION: Changes or modifications not expressly approved by Miltronies could void the user’s authority to operate this device. oe Fort Alert Systoms Rev. 2014-12-48 Copytignt © 2014 Mitronics Manufacturing ne 18Page 11 of 2Made Better In The USA by: Phone: (603) 352-3333 Mitonies Manufacturing, Ine Sales: (800( 826-9088 art iltronics res ce : eters FCC Statement This device complies with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation. ‘This equipment has been tested and found to comply with the limits for an unintentional radiator pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause interference to radio or television reception or if this device is experiencing poor reception due to interference, which can be determined by turning the equipment off and on, the user is encouraged to try to comect by one or more of the following: (1) Reorient of relocate the receiving antenna (2) Increase the separation between the equipment and the receiver (3) Connect the equipment into an outlet on a circuit different from the circuit with the receiver (4) Consult the dealer or an experienced radio/TV technician for help. Made Better In The USA by: Miltronics Manufacturing, Inc. 95 Krif Road, Keene, NH 03431 Main Office: 603-352-3333 Technical Support: 603-355-6677 Email: [email protected] —. Forkin Aler™ Systems Rev. 2014-12-48. ae Copyright® 2014 mitronics Manufacturing ne 18Page 12 of 12