TITLE:	ES&H Manual
DOCUMENT ID:	6145 Appendix T3 Inspection and Maintenance Requirements – Forklifts and Attachments

1.0 Purpose

Jefferson Lab requires periodic inspection and regular maintenance of forklifts and attachments used on its behalf. ES&H Manual Chapter 6140 Appendix T3 Inspection and Maintenance Procedure for Material Handling Equipment provides the minimum requirements for all material handling equipment. It is based on Occupational Safety and Health Administration (OSHA) and the American Society of Mechanical Engineers national standards.

Additional requirements specific to forklifts and attachments used on behalf of Jefferson Lab are provided below.

2.0 Scope

This appendix defines additional inspection requirements for:

· Forklift equipment and attachments owned or leased by Jefferson Lab, and

· Subcontractor provided forklifts and attachments.

Process steps are performed in coordination with ES&H Manual Chapter 6140 Material Handling Equipment Program and ES&H Manual Chapter 6145 Material Handling Equipment – Forklifts and Attachments.

3.0 Responsibilities

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

3.1 Qualified Forklift Operators — Includes anyone approved to use a forklift on behalf of Jefferson Lab.

· Perform inspection and maintenance as required by this procedure.

3.2 Material Handling Safety Representative (MHSR)

· Coordinate periodic inspection, maintenance, and repair requirements for forklifts operated on behalf of Jefferson Lab.

· Ensure accurate record keeping in accordance with the requirements of ES&H Manual Chapter 6140 Material Handling Equipment Program.

4.0 Process Steps

4.1 Determination

Each equipment inspection must conclude with one of the following determinations for the equipment’s status:

· Satisfactory for Use – continue with work plan.

· Requires a More Detailed Inspection– One/some/all items may be defective.

o Lock the machine out of service (see ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure, and

o Immediately contact the MHSR.

· Remove from Service – requires repair or replacement.

o Lock the machine out of service (see ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure, and

o Immediately contact the MHSR.

4.2 Forklifts

4.2.1 Inspections

Step 1: Operators perform pre-operational inspections of forklift and attachments in accordance with the equipment’s operating manual and using the appropriate Forklift Daily Checklists.

· If damage or malfunction is discovered proceed to Step 2.

· If no damage or malfunction is discovered continue with work.

Step 2: Lock out the equipment using ES&H Manual Chapter 6110 Lock, Tag, Try (LTT) Program and associated procedures.

Step 3: Report the damage or malfunction to the MHSR.

4.2.2 Maintenance

Step 1: Monthly preventive maintenance and semi-annual safety inspections are coordinated by the MHSR (currently through an authorized subcontracted service organization). Records of the findings are maintained by the MHSR for each forklift.

4.3 Forklift Attachments

4.3.1 Pre-Use Inspection

Step 1: Prior to each use the forklift operator inspects the attachment to ensure:

· The nameplate is in place and markings are legible.

· 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.

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

o Bent members,

o broken welds,

o bent or broken bolts.

Step 2: Verify that the attachment is approved for use with the selected forklift. The forklift dataplate must list the specific attachment.

4.3.2 Periodic Inspection and Maintenance

Forklift attachments and load suspending device are inspected and serviced annually. A written inspection report is maintained by the Material Handling Engineering Representative (MHER) for each attachment and device.

Step 1: Inspection Criteria

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

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

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

· Verify that the nameplate is in place and markings are legible.

· 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.

· Ensure attachment does not show signs of damage or failed components. Look for:

o bent members,

o broken welds,

o bent or broken bolts.

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

4.4 Lifting Devices

Are maintained and used with Jefferson Lab forklifts. These devices do not affect the capacity or safe operation of the truck. They are visually inspected for damage, or wear prior to use.

· Shield block lifters – Used to assist in the occasional and repetitive movement of shield blocks.

· Single Hook Fork Beam – Used to assist in the occasional and repetitive movement of loads suspended under the tines.

5.0 Revision Summary

Revision 1.2 – 04/23/13 – Added Forklift Inspection Video button link.

Revision 1.1 – 03/27/13 – Periodic review: No substantive changes required – updated Forklift Daily Checklist.

Revision 1 – 04/12/10 – Updated to reflect current laboratory operations.

ISSUING AUTHORITY	TECHNICAL POINT-OF-CONTACT	APPROVAL DATE	REVIEW REQUIRED DATE	REV.
ESH&Q Division	Dave Kausch	04/12/10	04/12/16	1.2

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 4/23/2013.