1.0 PURPOSE
The purpose of this procedure is to ensure safe operation and maintenance of fork trucks.
2.0 RESPONSIBILITY
It is the responsibility of the site manager/superintendent to ensure the implementation of this procedure and the employees all rules and regulations regarding fork truck safety.
3.0 REFERENCES
OSHA 29CFR 1910.178
NFPA No. 30
NFPA No. 58
4.0 DEFINITIONS
4.1 Fork Truck – A powered industrial truck with a pronged platform that can be raised or lowered and may be used to lift and transport materials (also called a lift truck, a high/low, a stacker-truck, trailer loader, side loader, tow-motor, or a fork hoist).
5.0 PROCEDURE
5.1 General Requirements for Fork Trucks
5.1.1 In areas where chemical, electrical, or fire hazards may exist only trucks that meet the area hazards classification are to be used. Information on appropriate truck selection is provided in OSHA 29 CFR 1910.178(b).
5.1.2 Fork trucks must be labeled by the manufacturer to indicate the areas where they can be used.
5.1.3 Fork trucks are not to be modified or added to without the manufacturer’s prior written approval. When modification/additions are made, truck capacity, operation, and maintenance instruction plates, tags, and/or decals must be changed accordingly.
5.1.4 If fork trucks are equipped with front-end attachments other than factory installments, they must be marked by that manufacturer. That manufacturer will identify those attachments and show the approximate combinations at maximum elevation with the load laterally centered.
5.1.5 Fork trucks shall have a working signal alarm while backing up.
5.1.6 Eye protection is mandatory is the fork truck does not have an enclosed cab.
5.2 Fork truck Operating Rules
5.2.1 Do not allow anyone to stand or pass under the elevated forks.
5.2.2 No passengers are allowed to ride the fork truck.
5.2.3 Do not place arms, legs, or hands between the uprights of the mast or outside the roll cage.
5.2.4 Forks are to be fully lowered, controls neutralized, power shut off, brakes set when fork truck is left unattended. Wheels are to be chocked when the fork truck is parked on an incline.
5.2.5 Trailers, railroad cars must have brakes set/wheels chocked while loading/unloading with a fork truck. Jack stands must be securely positioned under trailer if no tractor is attached.
5.2.6 Operators must verify trailer chocks, supports, and dock plates before loading/unloading.
5.2.7 Operators are to ensure sufficient headroom exists beneath overhead installations, e.g., lights, pipes, sprinkler systems, etc.
5.2.8 Never use a fork truck that is defective or unsafe to operate. A “DO NOT USE/OPERATE TAG” is to be attached to the steering wheel until repaired.
5.2.9 Seat belts (if provided) must be worn while operating a fork truck.
5.2.10 Operators will only use the fork truck in the manner for which it was designed and intended for.
5.3 Fork truck Travel
5.3.1 Face in the direction of travel except if the operator is carrying large loads, i.e., more than one pallet of material, etc.
5.3.1.1 The fork truck may be operated in reverse as long as the load is protected by the backrest extension so the load is prevented from falling rearward.
5.3.2 When ascending or descending grades over 10 %, drive loaded fork trucks with load upgrade.
5.3.3 Forks are to be tilted back and raised as far as necessary to clear the road surface.
5.3.4 Operate the fork truck at a speed that permits stopping in a safe manner.
5.3.5 Reduce speed and cross railroad tracks diagonally wherever possible.
5.3.6 Stunt driving and horseplay is not permitted.
5.3.7 Ensure dock boards or bridge plates are secured before they are driven over. Never exceed their rated capacity. The vehicle (truck, rail car) to be entered must have the brakes set and the wheels chocked.
5.3.8 When entering an elevator, approach slowly, neutralize controls, shut off power, and set brakes.
5.3.9 Reduce speed to a safe level when negotiating turns.
5.3.10 Reduce speed and sound the horn at cross aisles and other locations where vision is obstructed.
5.4 Fork truck Loading
5.4.1 Know the weight of the load and do not exceed the rated capacity of the fork truck.
5.4.2 The forks are to be placed under the load as far as possible; the mast carefully tilted backward to stabilize the load.
5.4.3 Use care when tilting the load forward or backward. When stacking or tiering, use only enough backward tilt to stabilize the load.
5.4.4 It is recommended to only move one pallet at a time, where practical. However, if it is necessary to lift more than one pallet, the operator must be able to see in the direction of travel and the load must be protected by the backrest extension so the load is prevented from falling rearward.
5.4.5 Do not add fuel while the engine is running.
5.4.6 Spillage of oil or fuel must be cleaned up and the fuel cap replaced before restarting the engine.
5.4.7 Do not operate a fork truck that has a fuel system leak.
5.5 Fuel Handling and Storage
5.5.1 Liquid fuels such as gasoline and diesel fuel will be stored and handled per NFPA Flammable and Combustible Liquids Code Number 30.
5.5.2 Liquefied petroleum gas fuel will be stored and handled per NFPA Storage and Handling of Liquefied Petroleum Gases Number 58.
5.5.3 When fueling a fork truck, the engine must be shut off and no smoking or open flames are permitted within the immediate area.
6.0 TRAINING REQUIREMENTS
6.1 Only trained and certified operators are allowed to operate fork trucks.
6.2 Training will be provided by a qualified instructor.
6.3 Operators of fork trucks will receive training on truck inspection, operations, and routine care procedures prior to operating and at least once every three years thereafter.
6.4 Initial training will consist of formal instruction, e.g., discussion, interactive computer learning, written material, and demonstrations performed by the trainer and practical exercises performed by the trainee.
6.4.1 The training content will include load capacity, instructions, distances, refueling, ramps, visibility, balances, and counterbalances.
6.4.2 A written and performance test will be used to measure knowledge and skill. Upon successful completion, personnel will be certified to operate the specific fork truck model.
6.4.3 The hands-on fork truck driving/operations training will require students to lift, move, and lower loads, as well as negotiate at least one sharp turn (45 degrees) while moving a load.
6.5 Refresher training will be conducted when:
6.5.1 Driver has been found to operate in an unsafe manner.
6.5.2 A near miss or incident has occurred with a fork truck.
6.5.3 Driver fails the 3-year evaluation/recertification.
6.6 Fork truck operators will be evaluated every three years to verify competency, using a performance check sheet that measures operation and inspection techniques.
6.7 Competent persons/users must be trained to properly use and inspect a safety platform/personnel basket.
7.0 DAILY FORKTRUCK INSPECTIONS
7.1 Fork trucks are to be thoroughly inspected daily or at the beginning of each shift by the operator and are not to be used if the inspection reveals any condition adversely affecting the safe operation of the truck.
7.2 A pre-shift inspection form (NCS Form 041 or equivalent) is to be completed to document each inspection and remain on the fork truck or other accessible location until the next inspection is completed. These are the minimum inspection requirements listed on this form.
7.3 If conditions are found which the inspector believes could affect the safe operation and use of the truck, take the truck out of service, and immediately write a work notification to report and correct deficiencies.
7.4 Checklist will be maintained on the fork truck until the deficiency is corrected.
7.5 The inspector must attach a Do Not Use/Operate Tag to the fork truck or the vehicle should be locked out.
8.0 FORKTRUCK MAINTENANCE
8.1 Fork truck owners are to ensure fork trucks are maintained per the manufacturer’s recommendations. Records are to include:
8.1.1 Fork truck ID
8.1.2 Description (manufacturer, model, capacity, etc.)
8.1.3 As found condition/action taken
8.1.4 Last date checked
8.1.5 Next check date
8.2 Fork truck owners will maintain fork truck maintenance records for as long as the truck is still in use at that facility.
8.3 Only authorized personnel shall make fork truck repairs.
8.4 Replacement parts of equal or better quality are to be used.
8.5 Fork trucks, their parts, or positions of the parts are not to be altered from how they were original without prior written approval from the manufacturer.
8.6 Fork truck must pass a safety inspection prior to being placed in service. The inspection is to be conducted before each shift when in operation. Utilize NCS Form 041 or equivalent (from facility owner).
8.7 Remove fork trucks from service should any part of the truck (i.e., radiator, hydraulics, etc.) are found to be in excessive of its normal operating temperature.
8.8 Fork trucks are to be kept in a clean condition, free of excess oil, and grease with the use of non-combustible cleaning agents.
8.9 Battery charging facilities will be provided by the fork truck owner for flushing and neutralizing spilled electrolyte including an eyewash and safety shower, and they shall have fire protection. The charging apparatus must be protected from trucks and must have adequate ventilation for dispersal of fumes from gassing batteries.
8.10 Reinstalled batteries shall be properly positioned and secured in the truck.
8.11 When charging batteries, acid is to be poured into water; water is NEVER TO BE POURED INTO ACID.
8.12 Trucks are to be properly positioned and brake applied before attempting to change or charge batteries.
8.13 Vent caps are to be checked for proper functioning. The battery (or compartment) cover(s) is to be open to dissipate heat.
8.14 Precautions will be taken to prevent open flames, sparks, or electric arcs in battery charging areas.
8.15 Tools and other metallic objects are to be kept away from the top of uncovered batteries.
9.0 APPENDICES
9.1 NCS Form 041 – Operator’s Pre-use Safety Inspection Checklist