The purpose of this document is to define requirements for
safe operations for use of low lift and high lift forklifts.
This appendix
provides detailed instructions for the proper maintenance and operation of
forklifts; and provides guidance for material handling aspects of operations.
3.0
Responsibilities
Refer to ES&H
Manual Chapter 6145 Forklift Safety for the list of responsibilities
associated with this appendix.
·
Operators perform pre-operational inspections of
forklift and attachments in accordance with the equipment’s operating manual
and using the appropriate Forklift Daily Checklists.
·
Monthly preventive maintenance is coordinated by
the Material Handling Safety Representative (MHSR) (currently through an
authorized subcontracted service organization).
Preventive maintenance records are maintained by the MHSR for each
forklift.
·
Semi-annual safety inspections are coordinated
by the MHSR (currently through an authorized subcontracted service
organization). Records of inspections
are maintained by the MHSR for each forklift.
·
If any of these inspections identify a condition
that could lead to unsafe operation, the equipment is locked and tagged in
accordance with ES&H Manual Chapter 6110 Lock, Tag, and Try
(LTT) Policy and the MHSR is notified.
4.2
Pre-Work Analysis
·
Forklift
operators and their supervisors familiarize themselves with the area of
operation noting any unusual conditions and perform a Task Hazard Analysis as required.
·
Select the proper forklift
for the job, diesel/propane or electric powered forklift. (For example: Indoor use of diesel/propane
forklifts is kept to a minimum. They may
be used to move a load in or out of a building, but not within a building.)
·
Evaluate the driving surface and tire-type:
o Pneumatic-type tires: asphalt, concrete, or improved (graveled).
o Solid-type tires: asphalt or concrete surfaces.
·
A forklift
attachment is a modification or addition to a forklift that affects its
capacity, stability, or safe operation.
Jefferson Lab maintains several items that fit into this category:
o
Jib booms are available for use
with certain forklifts as authorized by the manufacturer. Contact the Material Handling Equipment
Representative (MHER) to discuss boom capacities during lift planning. Additional training is required for use.
o
Drum lifter attachment is available
for use on one forklift. Additional
training is required for its use.
·
Lifting
devices are also maintained for use with forklifts. These devices do not affect the capacity or
safe operation of the truck
o
Shield block lifters – Used
to assist in the occasional and repetitive movement of shield blocks.
o
Single Hook Fork Beam – Used
to assist in the occasional and repetitive movement of loads suspended under
the tines.
4.4
Guides
and Signalers
·
The need for guides and signalers is identified through a Task Hazard Analysis, and is determined by
load size or proximity of hazards.
However an operator can request this type of assistance at any time.
·
Must be in the operator’s
view at all times.
·
Remain away from the
raised load. Guides and signalers
maintain a distance of at least one foot from the load for every foot the load
is raised.
4.5
Forklift Operations
·
Hardhats are worn by operators, guides, and
signalers when the forklift operation involves lifting the load more than
six-feet above the floor.
·
Forklifts are not operated
on public highways beyond the Jefferson Lab site boundaries.
·
Operators, guides and signalers concentrate on the operation of the forklift and the load. The work must be stopped if a distraction is
present.
·
Electric forklifts are charged in approved charging areas which
have an eye wash station located nearby.
·
At the conclusion of the forklift operation, the operator
immediately restores the work area to its pre-work condition, replacing
barriers, ropes, or other items moved for travel or delivery of the load.
“The
following shall apply to all personnel involved in forklift operations. At the
initial stage of the planning process, an appointed person shall classify each
lift into one of the DOE-specified categories (ordinary, critical, or
preengineered production).
Note:
Preengineered Production lifts are not defined for Jefferson Lab material
handling operations. A Standard
Operating Procedure or Temporary Operational Safety Procedure will be used as
apropriate for forklift operations that are beyond the scope of an ordinary
lift.
10.5.1
CONDUCT OF OPERATOR
The
following requirements shall be observed by the operator when operating
forklift trucks.
10.5.1.1
General
a. Safe operation
is the responsibility of the operator. Report all accidents and “near misses”
promptly.
b. The operator
shall develop safe working habits and also be aware of hazardous conditions in
order to protect himself, other personnel, the truck, and other material.
c. The operator
shall be familiar with the operation and function of all controls and
instruments before operating the truck.
d. Before operating
any truck, the operator shall be familiar with unusual operating conditions
which may require additional safety precautions or special operating
instructions.
e. Be certain the
truck has successfully passed a preuse inspection.
f. Do not start or
operate the truck, any of its functions or attachments, from any place other
than from the designated operator’s position.
g. Keep hands and
feet inside the operator’s designated area or compartment. Do not put any part
of the body outside the operator compartment of the truck.
h. Never put any
part of the body within the reach mechanism of the truck or other attachments.
i.
Avoid
reaching through the mast for any purpose.
j.
To
safeguard pedestrians, understand the truck’s limitations and observe the
following precautions:
1. Do not drive a
truck up to anyone standing in front of an object.
2. Ensure that
personnel stand clear of the rear swing area before conducting turning
maneuvers.
3. Exercise
particular care at cross aisles, doorways, and other locations where
pedestrians may step into the path of travel of the truck.
4. Do not allow
anyone to stand or pass under the elevated portion of any truck, whether empty
or loaded.
k. Do not permit
passengers to ride on powered industrial trucks unless a safe place to ride has
been provided by the manufacturer.
l.
Ensure
that fire aisles, access to stairways, and fire equipment is kept clear.
m. A powered
industrial truck is considered unattended when the operator is more than 25 ft.
(7.6 m) from the truck, which remains in his view, or whenever the operator
leaves the truck and it is not in his view.
n. Before leaving
the operator’s position, the operator shall perform the following:
1. Bring truck to a
complete stop.
2. Place
directional controls in neutral.
3. Apply the
parking brake.
4. Fully lower
load-engaging means, unless supporting an elevated platform.
o. In addition,
when leaving the truck unattended the operator shall perform the following:
1. Stop the engine
or turn off the controls.
2. If the truck
must be left on an incline, block the wheels.
3. Fully lower the
load-engaging means.
p. Maintain a safe
distance from the edge of ramps, platforms, and other similar working surfaces.
q. intentionally ommitted for JLab
r.
intentionally
ommitted for JLab
s. intentionally ommitted for JLab
t.
intentionally
ommitted for JLab
u. intentionally ommitted for JLab
v. intentionally ommitted for JLab
w. intentionally ommitted for JLab
x. Care shall be
taken to not contact overhead installations such as lights, wiring, pipes,
sprinkler systems, etc. If in doubt,
measure.
y. Motorized hand
trucks shall not be ridden unless they are of the hand/rider design.
10.5.1.2
Traveling
a. Observe all
traffic regulations and under all travel conditions, operate the truck at a
speed that will permit it to be brought to a stop in a safe manner. Unless
facility specific procedures state otherwise, the guideline is: within plant buildings
– 5 mph; on plant roads – 15 mph. Drive slowly around curves.
b. Yield the right
of way to pedestrians and emergency vehicles. Whenever possible, establish eye
contact with approaching pedestrians or vehicle drivers before continuing.
c. Do not pass another
truck traveling in the same direction at intersections, blind spots, or at
other locations where vision is obstructed.
d. Slow down and
sound horn at cross aisles and other locations where vision is obstructed.
e. Intentionally ommitted for JLab
f. Never travel
with forks raised to unnecessary heights. Approximately 4 to 6 inches (10 to 15
cm) above floor level is adequate.
g. Intentionally ommitted for JLab
h. Face in the
direction of travel, except if the load being carried obstructs forward view.
In such cases, travel with the load trailing.
i.
When
ascending or descending grades, ramps, and inclines:
1. In excess of 5
percent grade, drive loaded rider trucks with the load upgrade.
2. Use low gear or
slowest speed control.
3. Operate unloaded
trucks with the loadengaging means downgrade.
4. The load and
load-engaging means shall be tilted back, if applicable and raised only as far
as necessary to clear the road surface.
5. Avoid turning if
possible, and normally travel straight up and down.
j.
While
turning, be cautious of rear end swing and keep clear of the edge of loading
docks.
k. Make starts,
stops, turns, or direction reversals in a smooth manner s as not to shift load
and/or overturn the truck.
l.
Do
no indulge in stunt driving or horseplay.
m. Slow down for
wet and slippery floors.
n. Before driving
over a dockboard or bridge plate, be sure that it is properly secured.
o. Drive carefully
and slowly across the dockboard or bridge plate, and never exceed its rated
capacity.
p. Intentionally omitted for JLab
q. Unless a towing
hitch is supplied by the manufacturer, do not use forklift trucks as tow
trucks. When a towing hitch is provided, use tow bars rather than wire rope for
towing.
r.
At
the end of the operator’s shift, return the forklift truck to its assigned
parking place, set brakes, fully lower load-engaging means, place controls in
neutral position, turn ignition off, and secure the key.
s. If the truck is
equipped with a seat belt, use it.
10.5.1.3 Loading
a. Since the load
rating for forklifts may be based on stability or hydraulic or structural
competence, do not exceed the rated capacity in operational application.
b. The designated
person shall ensure that the weight of a load approaching the rated capacity
(combination of weight and location of the center of gravity) has been
determined within –10 percent, +0 percent before it is lifted.
c. Only stable,
safely arranged loads shall be handled. Block and secure them if necessary.
d. Caution shall be
exercised when handling off-center loads which cannot be centered.
e. Always spread
the forks to suit the load width.
f. Extra caution s
required when handling loads exceeding the dimensions used to establish truck
capacity. Stability and maneuverability may be adversely affected.
g. The forks shall
be placed under the load as far as possible; the mast shall be carefully tilted
backward to stabilize the load.
h. Do not transport
loads or miscellaneous items within the operator’s compartment or other areas
of the truck, unless a secure area has been provided and designated by the
user.
i.
A
load backrest extension shall be used whenever necessary to minimize the
possibility of the load or part of it from falling rearward.
j.
Do
not attach or operate any attachment on a forklift truck that has not been
approved for use by forklift truck manufacturer or a qualified engineer in the
absence of manufacturer approval.
k. When attachments
are used, extra care shall be taken in securing, manipulating, positioning, and
transporting the load.
l.
Operate
trucks equipped with attachments as partially loaded trucks when not handling a
load.
m. Fork length should
be at least two thirds of the load length.
n. Use extreme care
when tilting load forward or backward, particularly when high tiering.
o. Do not tilt
forward with forks elevated except to pick up or deposit a load over a rack or
stack.
p. When stacking or
tiering, use only enough backward tilt to stabilize the load.
q. Rigging loads
from the tines of a forklift, (attaching rigging to the forks to support a
suspended load) shall only be performed by qualified personnel in accordance
with approved site procedures.
r.
Never
lift with one fork without an engineering analysis and approval.
s. Use guides and
signalers as necessary. If in doubt, check the conditions personally before
proceeding. Standard hand signals are shown in Figure 10.5, “Hand Signals.”
t.
Do
not block fire extinguishers, fire protection sprinklers, or alarm stations
when stacking loads.
10.5.2 Intentionally omitted for JLab
10.5.3 STANDARD
HAND SIGNALS
a. Standard hand
signals for use at DOE locations shall be as specified in the latest edition of
the ANSI standards for the particular forklift being used (see Figure 10-5).
b. The operator
shall recognize signals only from the designated signaler. However Obey a STOP
signal no matter who gives it.
c. For operations
not covered by standard hand signals, special signals shall be agreed on in
advance by both the operator and the signal person, and should not conflict
with the standard signals.
