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

·         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 to a task qualified Jefferson Lab employee at the discretion of the responsible manager.

 

3.1              Qualified Forklift Operatorsincludes anyone approved to use a forklift on behalf of Jefferson Lab.

·         Perform inspection and maintenance as required by this procedure.

 

3.2              Material Handling Manager (MHM)

·         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. Refer to ES&H Manual Chapter 6110 Appendix T1 Lock, Tag, Try (LTT) Procedure.

o   Immediately contact the MHM.

·         Remove from Service – requires repair or replacement.

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

o   Immediately contact the MHM.

 

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 Hazardous Energy Control (HEC) Program and associated procedures.

 

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

 

4.2.2        Maintenance

 

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

·         The restraint mechanism is in place and functional (restraint mechanisms are normally chains with hooks or shackles on the ends, which hold the attachment in the proper position on the forklift tines during use).

·         The attachment does not show signs of damage or failed components; check 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 Manager (MHM) 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 (restraint mechanisms are normally chains with hooks or shackles on the ends, which hold the attachment in the proper position on the forklift tines during use).

·         Ensure attachment does not show signs of damage or failed components; check 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 wear and damage 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 1.6 – 02/25/21 – Changed ‘ESH&Q’ to ‘ES&H’; updated contact information; corrected hyperlinks; updated link title referencing ‘Lock, Tag and Try’ to ‘Hazardous Energy Control’ to reflect new title of Chapter 6110; other minor edits. No approval required.

Revision 1.5 – 01/24/18 – Updated TPOC from B.Sperlazza to M.Loewus

Revision 1.4 – 02/09/17 – Updated TPOC from D.Kausch to B.Sperlazza per B.Sperlazza

Revision 1.3 – 12/17/15 – Eliminated two positions previously identified as the MHSR and the MHER, the responsibilities of these positions are now performed by the MHM.

Periodic Review – 06/03/15 – No changes per TPOC

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

Revision 1.1 – 03/27/13 – Periodic Review; updated Forklift Daily Checklist  

Revision 1.0 – 04/12/10 – Updated to reflect current laboratory operations

 

 

ISSUING AUTHORITY

TECHNICAL POINT-OF-CONTACT

APPROVAL DATE

REVIEW DATE

REV.

ES&H Division

Mark Loewus

01/24/18

02/25/24

1.6

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 3/4/2021.