Forklift Motorized Pallet Jack Operator Safe Practices

I.Scope

This program supports compliance with the OSHA Standard 1910.178, Powered Industrial Trucks. The rules and practices in this policy apply to all company employees who are responsible for the operation of powered industrial trucks (includes both sit-down counterbalanced forklifts and motorized pallet jacks)at company facilities.

II.Purpose

The intent of this procedure is to promote the safe operation of powered industrial trucks. Only trained and competent operators are permitted to operate the powered industrial trucks.

III.Definitions

  1. Authorized Operator - Company employee who has satisfactorily completed both classroom training and aperformance evaluation on powered industrial trucks at the Company facilities.
  1. Rated Capacity - The maximum weight that the forklift is designed to lift as determined by the manufacturer.
  1. Load Center - The distance from the heel of the forks to the center of the load. A forklift’s rated capacity is based on a load center of 24 inches. When the load is carried at a greater distance than the load center, the maximum capacity of the truck is reduced.
IV.Responsibilities
A.Management
  1. Provide adequate training in safe operation of all powered industrial trucks.
  2. Provide equipment that is safe to operate.
  3. Implement an “Out of Service” policy for equipment that is damaged and does not meet safety standards.
  4. Not allow modification to equipment except those authorized in writing by the equipment manufacturer.
B.Supervisors
  1. Ensure only trained and competent operators are permitted to operate powered industrial trucks.
  2. Ensure safe operating standards are strictly adhered to on a daily basis by monitoring the performance of operators and conducting on-the-spot corrections to eliminate unsafe acts.
  3. Ensure all equipment is safety checked daily.
  4. Tag “Out of Service” any damaged equipment
  5. Coordinate service and repairs with Fleet/Maintenance.
C.Trainers
  1. Ensure only trained and competent operators are permitted to operate powered industrial trucks.
  2. Issue and administer this policy.
  3. Conduct initial and refresher training.
  4. Administer the written test.
  5. Conduct the operator performance evaluationto assess the driving skills of the employees who are being authorized to operate powered industrial trucks in the Company facilities.
  6. Complete the Performance Evaluation Form.
  7. Maintain the training records of all employees included in the training sessions.
D.Employees
  1. Operate only that equipment for which they have been specifically trained and authorized.
  2. Conduct required daily pre-inspections and complete the appropriate inspection forms.
  3. Operate all powered industrial trucks in a safe manner consistent with the Company safe practices and operator qualification training.
  4. Report all equipment malfunctions and/or maintenance needs to their supervisor immediately, and remove damaged equipment from service.
V.PROGRAM ACTIVITIES
A.Equipment Inspection and Maintenance
  1. Before each shift, all powered industrial trucks will be inspected, specifically but not limited to:
  1. Steering Mechanism
  2. Mast, Carriage, Fork or Attachment
  3. Battery
  4. Lights
  5. Strobe Lights
  6. Back Up Alarms
  7. Horn
  8. Brakes
  9. Controls
  10. Tires

Refer to the Company Pre-Shift Inspection Report.

  1. A file will be maintained that lists the daily inspections of equipment. This file will be kept in the Warehouse Department and maintained by the Warehouse Manager.
  1. A maintenance log will be kept that identifies repair needs and corrective action taken for each powered industrial truck.
  1. All powered industrial trucks found to be in need of repair, defective or in any way unsafe, will be taken “Out of Service” immediately and restored to safe operating condition before placed back in service. No truck will be placed in service if an inspection shows any condition(s) adversely affecting the safety of the vehicle, or the employee.
  1. Modifications will not be performed on any powered industrial truck without prior written approval by the manufacturer.
  1. After repairs are completed, powered industrial trucks will be given a performance test by the mechanic to ensure that the equipment is safe to operate.
  1. Powered industrial trucks must be kept in a clean condition, free of dirt, excess oil and grease.
  1. Charging Batteries
  1. Battery charging installations must be located in areas designated for that purpose.
  1. Equipment must be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries.
  1. Smoking, open flames, sparks, or electric arcs are prohibited in the battery charging area.
  1. Battery charging operations must be performed by trained and authorized personnel only.
  1. Emergency eyewash equipment must be maintained in the charging area (Refer to the Emergency Eyewash Inspection Procedure).
  1. Powered industrial trucks must be properly positioned (forks lowered) and brake applied before attempting to charge the battery.
  1. When charging batteries, pour acid into water. DO NOT pour water into the acid.
  1. A carboy tilter or siphon must be provided for handling electrolyte.
  1. Care shall be taken to assure that the vent caps are functioning. The battery (compartment) cover(s) shall be open to dissipate heat.
  1. Keep the vent caps in place to prevent the spray of electrolyte when charging batteries.

NOTE: Batteries are a part of the counter weighting on forklifts. The use of an undersized battery reduces the load capacity of the forklift.

  1. Wear chemical splash goggles, face shield, neoprene gloves and sleeves, and a neoprene apron when checking, filling, charging or repairing batteries.
  1. Changing and Handling LP Gas Cylinders
  1. Changing and handling of LP gas cylinders must be performed by trained and authorized personnel only.
  1. Before removing the empty propane cylinder, allow the forklift to run until any residual propane gas in the fuel system has removed.
  1. Equipment must be turned off during the changing of LP gas cylinders.
  1. No lift truck will be operated with a leak in the fuel system. Remove the truck from operation and place an “Out of Service” tag on it.
  1. Handle LP gas cylinders with care. Do not drop, throw, roll or drag cylinders. A proper carrying device that will prevent damage to cylinders will be used when transporting gas cylinders.
  1. Store the cylinders where physical damage will not occur.
  1. Inspect the LP gas cylinders for sharp dents or gouges that could weaken the structure of the cylinder. Remove damaged cylinders from operations and place an “Out of Service” tag on it.
  1. Wear chemical splash goggles, face shield and neoprene gloves and sleeves when changing the LP gas cylinder.
  1. Smoking is prohibited around LP gas cylinders.
  1. Close the primary valve when the cylinder is in storage.
  1. In the LP Area, full cylinders are in the upright position and employ cylinders are in the upside down position.
D.Loading/Unloading Trucks and Trailers
(Refer to Loading/Unloading Trucks and Trailers).
  1. Operator Training
  1. New hirepowered industrial truck training will consist of classroom safety training to address the principles of powered industrial truck operations and a performance evaluation. The performance evaluation is designed to have the operator demonstrate to the trainer the proper and safe use of the powered industrial truck for the job to be performed by the operator. New employeeswill be trained on the specific equipment for which they will be authorized to operate.
  1. The new employees will be required to take a written test on powered industrial trucks safe practices and operations. Minimum acceptable score is 80%.
  1. After satisfactorily passing the written test, the new employee will be allowed to take the performance evaluation. If the new employee fails the written test, the new employee will not be permitted to take the performance evaluation until a retest is administered and a passing grade is achieved.
  1. The trainer will evaluate the operator’s performance and determine the operator to be competent to operate a powered industrial truck safely. The Performance Evaluation Form will be used to document the operator’s performance evaluation. After satisfactorily passing the performance evaluation, the new employee’ssafety performance will continue to be evaluated during the 8-week probation period.
  1. During the 8-week probationperiod, it will be the responsibility of the Supervisor to ensure that the new employee is performing their job properly and safely as an operator. The Company has the option to extend the 8-week probation period by an additional 4 weeks if needed.The Supervisor will monitor anddocument the safety performance of the new operator and provide feedback to that new operator. At the end of the probation period, the Supervisor will make the determination if the new employee successfully completed the probation period.
  1. All operators will be required to be evaluated every 3 years. The performance evaluation will consist of the hands-on training.
  1. Refresher training will be provided to an operator when
  2. The operator has been observed to operate the power industrial truck in an unsafe manner;
  3. The operator has been involved in an accident or near-miss incident;
  4. The operator has received an evaluation that reveals that the operator is not operating the powered industrial truck safely;
  5. The operator is assigned to drive a different type of powered industrial truck; or
  6. A condition in the workplace changes in a manner that could affect safe operation of the forklift.
  1. The trainer will certify that each operator has been trained and evaluated. Training certification will include the operator’s name, date of training, date of evaluation and the person(s) performing the training or evaluation.
  1. Failure to adhere to powered industrial truck safe practices and procedures will subject operators to disciplinary action.
  1. Truck Operations
  1. Only approved powered industrial trucks may be used in designated hazardous areas where hazardous atmospheres exist due to materials being handled, processed or used.
  1. Do not remove or deface the warning and instruction decals on the equipment.
  1. Forklift and rider pallet jacks must not be driven up to anyone in front of a fixed object.
  1. No employee will stand or pass under the elevated portion of a forklift.
  1. Never carry passengers.
  1. Keep feet, arms, hands and legs within the confines of the truck at all times.
  1. Do not get on or off a moving forklift or rider pallet jack.
  1. When a powered industrial truck is left unattended, loading engaging means must be fully lowered, controls must be neutralized, power must be shut off and brakes set. Forklifts will be considered “unattended” when the operator is 25 feet or more away, or when the vehicle is not in view. Ensure the forks are not creating a trip hazard when the forklift is not in use.
  1. Wheels must be blocked if the truck is parked on an incline.
  1. When the operator of an industrial truck is dismounted and within 25 ft. of the truck, still in his view, the load engaging means must be fully lowered, controls neutralized and the brakes set to prevent movement.
  1. Bring the forklift to a complete stop, turn the engine off, set the brake, and neutralize the controls prior to dismounting the truck.
  1. Forklifts will not be used to open or close overhead doors, freight doors and route delivery truck bay doors.
  1. Floors of trucks and trailers will be checked for breaks and weakness before they are driven on.
  1. When forklifts are being used for lifting personnel, an approved safety platform with guardrails and toe board will be used that is firmly secured to the lifting carriage and/or forks. Employees in the approved safety platform must wear a full body harness with a retractable lanyard. Neverlift someone by putting forks through a pallet or standing on the forks. The operator will remain at the controls of the lift truck while the personnel platform is elevated.
  1. Keep fire aisles, access to stairways, doors and fire equipment clear.
  1. Be careful getting on or off forklifts and motorized pallet jacks with wet or slippery shoes.
  1. Do not store or stand pallets on end. Store pallets in the designated storage areas no higher than six (6) feet.
  1. Counter-weighting of lift trucks is prohibited unless written approval is provided by the manufacturer.
  1. Traveling
  1. All operators are required to wear seatbelts while operating a forklift.
  1. Operators will not let anyone stand or ride the forks.
  1. Under all travel conditions the forklifts will be operated at a speed that will permit it to be brought to a complete stop, in a safe manner.
  1. A safe distance of three truck lengths will be maintained between forklifts being operated.
  1. The forklift will be kept under control at all times.
  1. Operators will not drive with their vision obstructed, or with forks of truck raised without a load. If the load blocks the operator’s view, the forklift must be driven backwards.
  1. Never drive a lift truck with forks of the lift truck more than four inches from the floor.
  1. Lift, lower, and carry loads with the mast tilted back.
  1. The operator will look in the direction of and scan the path of travel.
  1. Do not pass lift trucks traveling in the same direction at intersections, aisles and blind spots.
  1. The loaded forklift will be driven with the load upgrade when driving on ascending and descending grades greater than 10%.
  1. Do not make turns or sudden stops on dock plates.
  1. Sound the horn when going through doors, rounding blind corners or corning out of bays.
  1. Watch for pedestrians, obstacles and other vehicles. When in doubt use the horn.
  1. Do not raise or lower the load while moving. Never drive a lift truck with a raised load.
  1. When moving a lift truck into position, check clearances for overhead obstructions.
H.Loading
  1. Only stable or safely arranged loads will be handled.
  1. Only loads within the rated capacity of the powered industrial trucks will be handled.
  1. The load engaging means will be placed under the load as far as possible and the mast tilted backwards to stabilize the load.
  1. Tilting forward with the load engaging means elevated is not permitted except to pick up a load. An elevated load will not be tilted forward except when the load is in a deposit position over a rack or stack. When stacking or tiering only enough backward tilt to stabilize the load must be used.
  2. Make gradual turns and stops. Do not turn on ramps.

FORKLIFT SAFETY CHECKLIST

Operator's Daily Checklist - Internal Combustion Engine Industrial Truck - Gas/LPG/Diesel Truck
Record of Fuel Added

Date / Operator / Fuel
Truck# / Model# / Engine Oil
Department / Serial# / Radiator Coolant
Shift / Hour Meter / Hydraulic Oil

SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT)
Have aqualifiedmechanic correct all problems.

Engine Off Checks / OK / Maintenance
Leaks – Fuel, Hydraulic Oil, Engine Oil or Radiator Coolant
Tires – Condition and Pressure
Forks, Top Clip Retaining Pin and Heel – Check Condition
Load Backrest – Securely Attached
Hydraulic Hoses, Mast Chains, Cables and Stops – Check Visually
Overhead Guard – Attached
Finger Guards – Attached
Propane Tank (LP Gas Truck) – Rust Corrosion, Damage
Safety Warnings – Attached (Refer to Parts Manual for Location)
Battery – Check Water/Electrolyte Level and Charge
All Engine Belts – Check Visually
Hydraulic Fluid Level – Check Level
Engine Oil Level – Dipstick
Transmission Fluid Level – Dipstick
Engine Air Cleaner – Squeeze Rubber Dirt Trap or Check the Restriction Alarm (if equipped)
Fuel Sedimentor (Diesel)
Radiator Coolant – Check Level
Operator's Manual – In Container
Nameplate – Attached and Information Matches Model, Serial Number and Attachments
Seat Belt – Functioning Smoothly
Hood Latch – Adjusted and Securely Fastened
Brake Fluid – Check Level
Engine On Checks – Unusual Noises Must Be Investigated Immediately / OK / Maintenance
Accelerator or Direction Control Pedal – Functioning Smoothly
Service Brake – Functioning Smoothly
Parking Brake – Functioning Smoothly
Steering Operation – Functioning Smoothly
Drive Control – Forward/Reverse – Functioning Smoothly
Tilt Control – Forward and Back – Functioning Smoothly
Hoist and Lowering Control – Functioning Smoothly
Attachment Control – Operation
Horn and Lights – Functioning
Cab (if equipped) – Heater, Defroster, Wipers – Functioning
Gauges: Ammeter, Engine Oil Pressure, Hour Meter, Fuel Level, Temperature, Instrument Monitors – Functioning

Operator's Daily Checklist - Electric Industrial Truck
Record of Fluid Added

Date / Operator / Battery Water
Truck# / Model# / Hydraulic Oil
Department / Serial#
Shift / Drive Hour Meter Reading / Hoist Hour Meter Reading

SAFETY AND OPERATIONAL CHECKS (PRIOR TO EACH SHIFT)
Have aqualifiedmechanic correct all problems.

Motor Off Checks / OK / Maintenance
Leaks – Hydraulic Oil, Battery
Tires – Condition and Pressure
Forks, Top Clip Retaining Pin and Heel -- Condition
Load Backrest Extension – Attached
Hydraulic Hoses, Mast Chains, Cables & Stops – Check Visually
Finger Guards – Attached
Overhead Guard – Attached
Safety Warnings – Attached (Refer to Parts Manual for Location)
Battery – Water/Electrolyte Level and Charge
Hydraulic Fluid Level – Dipstick
Transmission Fluid Level – Dipstick
Operator's Manual in Container
Capacity Plate Attached – Information Matches Model, Serial Number and Attachments
Battery Restraint System – Adjust and Fasten
Operator Protection
Sit-down Truck - Seat Belt – Functioning Smoothly
Man-up Truck – Fall protection/Restraining means - Functioning
Brake Fluid – Check level
Motor On Checks (Unusual Noises Must Be Investigated Immediately) / OK / Maintenance
Accelerator Linkage – Functioning Smoothly
Parking Brake – Functioning Smoothly
Service Brake – Functioning Smoothly
Steering Operation – Functioning Smoothly
Drive Control – Forward/Reverse – Functioning Smoothly
Tilt Control – Forward and Back – Functioning Smoothly
Hoist and Lowering Control – Functioning Smoothly
Attachment Control – Operation
Horn – Functioning
Lights & Alarms (where present) – Functioning
Hour Meter – Functioning
Battery Discharge Indicator – Functioning
Instrument Monitors – Functioning
Forklift & Motorized Pallet Jack Performance Evaluation Form
Operator Name: / Type of Truck (Check Box):
Operator Signature: / Gas, L-P Trucks
Electric Sit-Down Rider Truck
Department: / Electric Stand-Up Rider Truck
Date of Performance Evaluation: / Motorized Rider Pallet Truck
Trainer Name: / Motorized Pallet Hand Truck
Trainer Signature:
Operator Performance Evaluation Checklist
S: Satisfactory / N=Needs Work / U=Unsatisfactory
Use the following items for evaluation of Operator’s driving performance. / S / N / U
1. Understands the Pre-Shift Inspections
  1. Shows familiarity with truck controls

  1. Slowed down at intersections

  1. Sounded horn at intersection

  1. Slowed down for ramps, dips, uneven ground, slippery surfaces

  1. Obey Signs & Postings

  1. Kept a clear view of direction of travel

  1. Turned corners correctly– was aware of rear end swing

  1. Yielded to pedestrians

10.Drove under control within proper traffic aisles
11.Approached load properly
12.Lifted load properly
13.Maneuvered properly
14.Traveled with load at proper height
15.Lowered load smoothly/ slowly
16.Stops smoothly/completely
17.Load balanced properly
18.Forks under load all the way
19.Checked bridge plates /ramps as necessary
20.Stacked loads evenly and neatly
21.Did drive backward when required
22.Did check load weights
23.Parked with:
  • forks on the floor

  • controls neutralized

  • brake on set

  • power off

Comments:

FORKLIFT TRUCK OPERATIONS