TITLE:	ES&H Manual
DOCUMENT ID:	6145 Appendix T2 Forklift Attachments Use and Inspection

1.0 Purpose

The purpose of this document is to describe forklift attachments approved for use with Jefferson Lab-owned forklifts and to outline the inspection requirements of these devices.

Forklift attachments introduce additional hazards that the operator must be aware of. Use of forklift attachments requires additional training not included in SAF 502 or 502A. Refer to ES&H Manual Chapter 6145 Forklift Safety for training requirements.

The Occupational Safety and Health Administration (OSHA) standard governing the safe use and operation of forklifts is titled Powered Industrial Trucks. This appendix uses “forklift” to describe these vehicles.

2.0 Scope

Forklift attachments described in this document are:

• Contrx Industries Model JLT424 - 2 Ton Telescoping Jib Boom
• Contrx Industries Model JLT630 - 3 Ton Telescoping Jib Boom
• T&S Equipment Co Model LM-OBT/6 - 3 Ton Orbital Telescoping Jib Boom
• Vestil Mfg. Corp. Eagle-Beak Drum Lifter

Forklift load suspending devices described in this document are:

• Jefferson Lab 24,000# S2 Shield Block Lifter
• Jefferson Lab 9,100# Pallett Crusher
• Caldwell Co. Model 10-2-20 Single Hook Fork Beam

3.0 Responsibilities

NOTE: Management authority may be delegated at the discretion of the responsible manager.

3.1 Material Handling Safety Representative (MHSR)

· Obtains forklift manufacturers approval to use an attachment with a specific forklift.

3.2 Material Handling Equipment Representative (MHER)

· Provides oversight of forklift attachment adequacy, annual inspection and operator training.

3.3 Forklift Operators

· Have current training for forklift attachments as described in the ES&H Manual Chapter 6145 Forklift Safety. Training is accomplished prior to using a forklift attachment.

· Inspect the forklift attachment before each use.

· Report damaged or missing pieces of forklift attachments to the MHSR.

· Do not allow anyone to use an attachment that you have in use.

· Return the attachment and key to their assigned location after each use.

3.4 Forklift Operators – Construction Sub Contractors

· Contact the SOTR if a use of an attachment well in advance of the intended use period.

4.0 Expectations

4.1 Forklift Attachment Pre-Use Inspection:

· Prior to each use the forklift operator inspects the attachment to ensure:

o The nameplate is in place and markings are legible.

o Verify that the restraint mechanism is in place and functional. (The restraint mechanism is generally chains with hooks or shackles on the ends which hold the attachment in the proper position on the tines during use.

o The attachment does not show signs of damage or failed components. Look for:

§ Bent members,

§ broken welds,

§ bent or broken bolts.

o Verify that the attachment is approved for use with the selected forklift. The forklift dataplate must list the specific attachment.

4.2 Forklift Attachments Use:

4.2.1 Telescoping Jib Booms

Introduce substantial changes to the stability of a forklift. The distance a load is suspended in front of the forklifts mast (static load) and the effects (bumps and dips) have on the load (dynamic load) result in significant reduction in the capacity that a forklift can safely lift.

· The load rating of a specific forklift and telescoping boom combination is determined by the forklift manufacturer.

· A load chart has been created for each telescoping boom indicating the load capacity at the various boom positions for each forklift that is approved for use. A load chart is attached to each boom.

· Determine the weight of the object to be lifted and the amount of boom extension necessary for a lift.

o Refer to the telescoping boom load charts to determine which boom/forklift combination has the required capacity at the desired boom hook position.

· Select rigging gear necessary to attach the load to the boom

o Rigging must be approved gear that complies with the requirements of American Society of Mechanical Engineers (ASME) B30.9 Slings and ASME B30.26 Rigging Hardware: Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings.

· Adjust the forks so that the inside width between the forks will fit into the fork pockets. At least one fork must be locked to the bedplate of the mast.

· Drive the truck forward to slip forks into the fork sleeves until the boom to the furthest position, away from the tips of the tines, against the mast. Attach safety chain to mast to secure the boom attachment in position.

· Accomplish the lift, using spotters and signalmen as needed.

o Many hook positions are available under the boom. The outer most position is generally the load carrying position when in use. The remaining hook positions may be rigged to steady the load as needed.

4.2.2 Drum Lifter

The eagle-beak drum lifter provides a convenient way to lift, transport and load 30- or 55-gallon single drums. The drums may be open and closed head plastic, steel and fiber drums with a top lip strong enough to support the weight of the drum and has a maximum capacity rating of 1000 pounds.

· Adjust the forks so that the inside width between the forks will fit into the fork pockets. At least one fork must be locked to the bedplate of the mast.

· Drive the truck forward to slip forks into the fork sleeves until the tips of the tines contact the closed end of the fork sleeves. Attach safety chain to mast to secure drum lifter attachment to the forks.

· Tilt the fork truck mast forward and drive the tuck with the forks near the floor level to center the lifter in front of the drum until the lifter contacts the drum at the bottom drum grip.

· With the mast still in the tilted forward position, raise the forks up.

· When the upper jaw on the drum lifter engages the top of the drum lip, straighten the mast and raise the forks to transport the drum.

· To release the drum, remove ratcheting strap. Lower the forks so that the drum sets flat on the floor and continue to lower forks until the upper jaw disengages itself.

4.3 Forklift load suspending device use:

4.3.1 Single Hook Fork Beam

Single hook fork beams are seldom used at Jefferson Lab; however, they provide positive handling of loads otherwise impractical for forklifts. Jefferson Lab maintains three fork beams, each rated for a 2,000 Lb. load. These devices do not require approval from the forklift manufacturer for use because they do not change the load carrying capacity or stability of the vehicle.

Forklift operators are authorized to use fork beams as needed in accordance with the following instructions. Contact the MHSR for introductory training and access to a beam.

· Adjust the forks so that the outside inside width between the forks is 20”. At least one fork must be locked to the bedplate of the mast. The tines should be near the center of the mast.

· Lift the 20# fork boom into position on the tines. The boom may be positioned near the mast or as far away from the mast as the forklift data plate will allow not to exceed a rated load center dimension.

· Tighten both screw retainers to contact the bottom of the tines.

· Select rigging gear necessary to attach the load to the boom

o The rigging must be approved gear that complies with the requirements of ASME B30.9 Slings and ASME B30.26 Rigging Hardware: Safety Standard for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings.

o Accomplish the lift, using spotters and signalmen as needed.

4.3.2 Jefferson Lab 24,000# S2 Shield Block Lifter

This device has been engineered and fabricated at Jefferson Lab to permit movement of individual 24,000# S2 Shield Blocks using the pre-engineered lift points of the shield blocks. This device does not require approval from the forklift manufacturer for use because it does not change the load carrying capacity or stability of the vehicle.

· The Hyster lift truck model H360XL (better known as Crusher) has the lifting capacity to lift and transport 24,000# shield blocks. No other forklift at Jefferson Lab has the capacity to use this lifting device.

· Adjust the forks so that the inside width between the forks will fit into the fork pockets. Both forks must be locked to the bedplate of the mast.

· Drive the truck forward to slip forks into the fork sleeves until the restraining tab firmly fixed to the block lifter passes the mast bedplate, lower the forks as needed to permit this positioning. Raise the forks to pick up the block lifter load then inspect the position of the restraining tab for proper engagement behind the mast bedplate.

· Center the block lifter over a S2 Shield Block and lower the block lifter sufficiently to permit engagement of the attached load hooks onto the pre-engineered lift points of the shield block.

· Raise the block lifter with suspended shield block load and transport to the desired location.

4.3.3 Jefferson Lab 9100# Pallet Crusher

This device has been engineered and fabricated at Jefferson Lab to permit the compaction of wood crates and pallets in an open top 40 cu yd dumpster. This device does not require approval from the forklift manufacturer for use because it does not change the load carrying capacity or stability of the vehicle.

· The Hyster lift truck model H360XL (better known as Crusher) has the lifting capacity to lift this device to the required height for compaction. No other forklift at Jefferson Lab has the capacity to use this lifting device.

· Adjust the forks so that the inside width between the forks will fit into the fork pockets. Both forks must be locked to the bedplate of the mast.

· Drive the truck forward to slip forks into the fork sleeves until the tips of the tines contact the closed end of the fork sleeves. Attach safety chain to mast to secure the pallet crushing device to the forks.

· Lower the pallet crushing device on top of wood crates and pallets placed in the dumpster to break the wooden members of the crates and compact the discarded material.

4.4 Forklift Attachment Periodic Inspection and Maintenance:

· Forklift attachments and load suspending device are inspected and serviced annually. A written inspection report is maintained by the MHER for each attachment and device.

· Inspection Criteria:

o Verify that the forklift data plates are in place on each forklift listed on the attachment load chart.

o Remove surface rust and lubricate all pivots and screw threads with light machine oil.

o Replace ratcheting strap on the eagle-beak drum lifter.

o The nameplate is in place and markings are legible.

o Verify that the restraint mechanism is in place and functional. (The restraint mechanism is generally chains with hooks or shackles on the ends which hold the attachment in the proper position on the tines during use.

o The attachment does not show signs of damage or failed components. Look for:

§ bent members,

§ broken welds,

§ bent or broken bolts.

o Inspect the carbon fiber cable locking mechanism for adequacy. Lubricate the lock wafers with a graphite lock lubricant.

5.0 References

5.1 29 CFR 1910.178 Powered Industrial Trucks

5.2 ANSI/ITSDF B56.1 – 2005 Safety Standard for Low Lift and High Lift Trucks

5.3 ES&H Manual Chapter 6145 Appendix T1 Use of Forklifts

5.4 ES&H Manual Chapter 6145 Forklift Safety

ISSUING AUTHORITY	APPENDIX AUTHOR	APPROVAL DATE	EFFECTIVE DATE	EXPIRATION DATE	REV.
ESH&Q Division	Dave Kausch	04/24/09	04/24/09	04/24/12	1

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the document is the same revision as the current on line file. This copy was printed on 9/3/2009.