Safety Regulations and Procedures MOTOR VEHICLE SAFETY Fork Lift Safety - S New 11/96

Transcription

1 PURPOSE STATE REGULATION To ensure personnel safety is the paramount consideration in using forklifts. Washington Administrative Code (WAC) , Powered Industrial Trucks. Contact Safety Services for a copy as needed. RESPONSIBILITIES Safety Services Directors/Supervisors Assist departments in developing and maintaining a forklift safety program. Permit only trained operators to operate a forklift. Training is discussed below. Maintain a Master Log of Qualified Forklift Operators who are trained, qualified and have authorization to operate forklifts. Use the form on page S Ensure forklift operations are performed in accordance with the district training. Employees Do not operate a forklift unless you have completed the district training program, and are qualified and authorized to do so by your department supervisor. Operate a forklift safely and in accordance with the district training program. TRAINING The warehouse supervisor will manage the district forklift training program. Training will consist of the "Forklift Safety" training program developed and produced by Comprehensive Loss Management, Inc. (CLMI). Key components of the program are: 1. A training guide; 2. A training video; 3. An employee manual; 4. This written program in the Safety & Transportation Manual; 5. Forklift Operator's Daily Checklist (see page S &.6); 6. Forklift Maintenance Log (see page S ); 7. Master Log of Qualified Forklift Operator's (see page ); 8. Forklift Operator's Written Learning Exercise (see page S ); and 9. Forklift Operator's Performance Skills Evaluation (see page S ). REQUIREMENTS Hazardous atmospheres Use forklifts only in environments free of hazardous gases and vapors. Guards Battery charging Battery charging (cont.) High lift forklifts shall be fitted with an overhead guard and vertical load backrest. Maintain a designated area for battery charging. Provide flushing and neutralizing capabilities for spilled electrolyte, for fire protection, Page 1 of 10

2 for protection from damage by other vehicles, and for adequate ventilation. When charging batteries, the vent caps should be kept in place to avoid electrolytic spray. Ensure the vent caps are functioning as designed. The battery (or compartment) cover(s) shall be open to dissipate heat. Ensure there is no smoking, flames, sparks or electric arcs in the area. Lighting Dockboards (bridge plates) Ensure lighting is adequate to perform the tasks assigned. Lighting which causes heavy shadows should be avoided and, or corrected. Dockboards shall be strong enough to carry the load imposed on them. Forklift Operations entrapment elevated hazard riders arms & legs unattended safe distance brakes/chocking overhead hazards raised platform Observe the following: Do not drive up to anyone standing in front of a fixed object such as a wall or pallet. No one is allowed to stand under the elevated portion of a forklift. No riders permitted. Keep arms and legs within the running lines of the forklift and never between the uprights of the mast. When unattended, the load engaging means shall be fully lowered, controls shall be neutralized, power shall be shut off, and brakes set. Wheels shall be chocked if unattended on an incline. Maintain a safe distance from the edge of ramps, docks and platforms. Brakes shall be set and wheels chocked to prevent movement of trucks, trailers or rail cars when operating a forklift. Ensure sufficient head room under overhead installations, lights, pipes, etc. A forklift may be used to raise a work platform if: The raised platform is securely attached to the forks and has standard guardrails and toeboards installed on all sides. The hydraulic system is designed to not drop faster than 135 feet per minute in the event of any failure; label the forklift accordingly. A safety strap shall be installed to prevent the boom from tilting. An operator shall attend (i.e., keep in visual contact and within 25 feet of the forklift) while workers are on the platform. Page 2 of 10

3 The forklift operator shall be in the normal operating position while raising or lowering the platform. The forklift will not travel while workers are in the platform except for "inching". The area between the workers on the platform and the mast shall be guarded to prevent contact with chains or other shear points. Traveling following cross aisles grades Observe the following: A safe distance shall be maintained of approximately three truck lengths. Slow down and sound the horn at locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall travel with the load trailing. On grades in excess of 10 percent keep the load upgrade. Keep the forks tilted back and raised only as high as necessary. speed Drive slowly at all times. Turn in a smooth, controlled manner. Loading Observe the following: stability capacity engaging tilting Engage only stable or safely arranged loads. Keep within the rated capacity of the forklift. Place forks under the load as far as possible. The mast shall be carefully tilted backward to further stabilize the load. Tilting forward with the fork raised is prohibited except to pick up a load. An elevated load shall not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering, use only enough backward tilt to stabilize the load. Daily/Shift Inspection The Operator's Daily Checklist will be filled out at the beginning of each day or shift. Operators will use the check list on page S (for electric powered lifts) or the checklist on page S (for gas, propane or diesel powered lifts). A forklift shall not be placed in service if the operator's inspection shows any condition adversely affecting the safety of the vehicle. Defects shall be reported to the supervisor immediately. records Maintenance/ The Operator's Daily Checklist will be maintained for at least two years. If at any time a forklift is found to be in need of repair, is defective, or is in any way unsafe, the truck shall be taken out of service by the supervisor until it has been Page 3 of 10

4 restored to safe operating condition. inspection records batteries alterations overheating Forklifts returning from repair will be inspected and operated, and certified ready for "return to service." The inspector will be a qualified forklift operator and designated in writing for the task by a supervisor. Record of the "return to service" certification will be recorded in the maintenance/repair log; certifier's initials required. See the "Forklift Maintenance Log" on page S A master forklift maintenance and repair file shall be maintained for at least two years. Batteries shall be disconnected to conduct maintenance. Forklifts shall not be altered by any means from the manufacturer's specifications. When the temperature of any part of any forklift exceeds its normal operating temperature, thus creating a hazardous condition, the vehicle shall be removed from service and not returned to service until the cause of such overheating has been eliminated. FORMS Forklift Operator's Daily Checklist; see page S &.6. Forklift Maintenance Log; see page S Master Log of Qualified Forklift Operator's; see page Forklift Operator's Written Learning Exercise; see page S Forklift Operator's Performance Skills Evaluation; see page S Page 4 of 10

5 Electric Forklift Operator's Daily Checklist Forklift Number:. Week Ending (date):. Hour Meter Reading: Date Date Date Date Date Visual Checks Obvious damage/leaks (1) Tire condition Battery plug connection Head & tail lights Warning lights Hour meter Other gauges & instruments Battery discharge (2) Fire extinguisher; charged? OPERATIONAL CHECKS Horn Steering (1) Service brakes (1) Battery load test (2) Parking brake (1) Seat interlock switch (1) Hydraulic controls Checked by: print name Initials Notes: (1) Report a problem with this check to your supervisor immediately. Page 5 of 10

6 (2) When key is turned on, gauge should indicate battery is charged. (3) Watch battery indicator while holding tilt lever on full back tilt. If needle moves to red area, battery doesn't have sufficient charge to operate truck properly. Gas, Propane or Diesel Forklift Operator's Daily Checklist Forklift Number:. Week Ending (date):. Hour Meter Reading: Date Date Date Date Date Visual Checks Obvious damage & leaks (1) Tire condition Radiator water level (2) Head & tail lights Warning lights Fuel level (2) Battery water level (2) Fire extinguisher; charged? OPERATIONAL CHECKS Horn Steering (1) Service brakes (1) Parking brake Hydraulic controls Checked by: print name Initials Notes: (1) Report a problem with this check to your supervisor immediately. (2) Driver replenish as needed. Page 6 of 10

7 FORKLIFT MAINTENANCE RECORD Forklift Number:. Model Number:. Serial Number:. Date Hour Meter Reading Maintenance Performed Initials Page 7 of 10

8 Master Log of Qualified Forklift Operators License # Name Department Forklift Truck Qualified to Operate Riding Stacker Walking Stacker Other Date Issued Page 8 of 10

9 Forklift Safety Learning Exercise Answer the following questions 'True' or "False' by circling the appropriate letter. T F 1. Material handling refers only to moving raw materials in a workplace? T F 2. Two common types of forklifts are counterbalance and narrow aisle? T F 3. The mast is the component of a forklift that holds the mechanism for raising and lowering the load? T F 4. Side stability refers to a forklift's ability to turn sharply? T F 5. The amount of weight a forklift can safely lift is called its 'Rated Capacity?" T F 6. Where a load sits is as important as how much it weighs? T F 7. A forklift should be inspected at least once a month? T F 8. To test the brakes, step on the pedal. If it doesn't go all the way down, the brakes are okay? T F 9. As the operator, you are responsible for the safe operation of the forklift? T F 10. You should never use a forklift for any purpose other than the one for which it was designed? T F 11. When another load is in front of the one you are picking, up, tilt the forks back as far as possible to clear the other load? T T T T T F 12. Stacking and unstacking must be done carefully because the higher you lift a load, the more unstable the forklift becomes? F 13. Lifting a load while traveling is okay as long as you are moving forward? F 14. If a load blocks your vision when in the driver's seat, stand up to see over the load? F 15. When following other forklifts, you should always maintain a safe distance of at least three forklift lengths? F 16. A forklift is considered to be unattended whenever it is parked? Name:. Department:. Trainer's Name:. Date:. Forklift Operations Performance Skills Evaluation Operator's Name:. Date:. Page 9 of 10

10 Place a mark (T) in the appropriate area. Good Fair Poor NA Inspects equipment both before and after each shift Demonstrates how each control is used Negotiates ramps properly with a two tier load Places forks properly - spaced as wide as possible Lifts load squarely and smoothly Engages horn at intersections Slows down at blind corners and all intersections; drives carefully Places dock plate in proper position Conveys load at a minimal distance from the floor Enters and exits a trailer with / without a load Turns key to OFF position, forks dropped to minimum distance from the floor with mast tilted forward when parking the forklift Turns off LP control valves when parking the forklift Performs refueling / recharging procedures safely Does not block pedestrian egress areas or fire fighting equipment with forklfit when parked Maintains a safe distance from the edge of the dock or other limiting operational situations Based on the operator's performance during this evaluation, the above named operator/person has demonstrated the ability to safely operate a forklift for Spokane Public Schools. Evaluator Signature:. Date:. Evaluator's Title:. Page 10 of 10