Powered Industrial Lift Truck/Forklift Safety

POWERED INDUSTRIAL LIFT TRUCK/FORKLIFT SAFETY

CORPORATE POLICY, REQUIREMENTS AND PROCEDURES
Purpose – To establish requirements for the use and maintenance of powered industrial trucks.
Definitions

Approved powered industrial lift truck – An industrial lift truck that is listed or approved for fire safety purposes for the intended use by a nationally recognized testing laboratory, using nationally recognized testing standards
Attachment – A device, other than conventional forks or load backrest extension, mounted permanently or removable on the elevating mechanism of the truck for handling the load.
Cantilever truck – A self-loading, counterbalanced or noncounterbalanced truck equipped with cantilever load engaging means.
Carriage – The support structure for forks or attachment, generally roller mounted, traveling vertically within the mast of a cantilever truck.
Counterweight – The weight that is a part of the basic structure of a truck that is used to offset the weight of a load and to maximize the resistance of the vehicle to tipping over.
Forks – Horizontal tine-like projections, normally suspended from the carriage, for engaging or supporting the load.
Forklift – A high-lift, self-loading industrial truck equipped with load carriage and forks for transporting and tiering loads.
Grade – The slope of a surface, which is usually measured as the number of feet of rise or fall over a 100-foot horizontal distance (the slope is expressed as a percent).
Lateral Stability – A truck's resistance to overturning sideways.
Load Engaging – A load-handling device attached to a powered industrial truck for the purpose of handling a load.
Longitudinal Stability – The truck's resistance to overturning forward or rearward.
Mast – A support member providing the guideways permitting vertical movement of the carriage. It is usually constructed in the form of channels or similar sections providing the supporting pathway for the carriage rollers.
Self-Loading – The capability of a truck to pick up, carry, set down and stack or tier its load without the aid of external means.
Tiering – A process of placing a load on or above another load.
General Requirements

All new powered industrial trucks (forklifts) shall meet the design and construction requirements for powered industrial trucks established in the "American National Standard for Powered Industrial Trucks, Part II, ANSI B56.1-1969.”
Modifications and additions, such as the use of “home-made” attachments, that affect the capacity and safe operation of powered industrial trucks shall not be performed without the prior written approval from the manufacturer.
All nameplates, markings, ANSI labels, load ratings, etc. shall be in place and maintained in a visible and legible condition.

Powered industrial trucks shall be marked to identify attachments and to show the approximate combined weight of the truck and attachments at maximum elevation and with the load laterally centered.

The following designations describe all available types of powered industrial trucks:

D– Diesel.

DS – Diesel with exhaust, fuel and electrical system safeguards.
DY – Diesel with exhaust, fuel and electrical system safeguards; but without electric parts.

E – Electric.

ES – Electric with spark protection.
EE – Electric with enclosed engine.
EX – Electric for flammable atmospheres.

G– Gasoline.

GS – Gasoline with exhaust, fuel and electrical systems safeguards.

LP – Liquefied petroleum gas.

PLS – Liquefied petroleum gas with exhaust, fuel and electrical systems safeguards.

The atmosphere or work environment in which a powered industrial truck will be used shall be assessed and classified as either hazardous or nonhazardous before powered industrial truck selections are made. Refer to the designations listed above, the use restrictions outlined in 29 CFR § 1910.178, and the use requirements detailed in Table N-1. – Summary Table on Use of Industrial Trucks in Various Locations contained in 29 CFR § 1910.178.
All powered industrial trucks shall meet or exceed the use requirements for the atmosphere or work environment in which it will be used.
All powered industrial trucks shall be fitted with an overhead guard. Overhead guards are intended to offer protection from the impact of small boxes, bagged material, concrete blocks, etc. that are representative of the job application, but not to withstand the impact of a falling capacity load.
All powered industrial trucks handling loads that are subject to shifting and falling rearward due to the size, geometry or nature of the load, shall be fitted with a vertical load backrest extension that is manufactured in accordance with the standards found in 29 CFR § 1910.178.
The storage and handling of fuels shall be in accordance with all applicable NFPA requirements.
Battery charging installations for electric powered industrial trucks shall be in designated areas which contain or provide:

Adequate facilities for flushing and/or neutralizing spilled electrolyte, including an eye wash station.

Adequate fire protection.

Adequate protection of charging apparatus from damage by trucks.

Adequate ventilation for dispersal of fumes from gassing batteries.

During the removal, charging or reinstalling of batteries, the following procedures shall be followed:

Smoking, open flames, sparks or electric arcs shall be prohibited in battery charging areas.

Powered industrial trucks shall be properly positioned with brakes applied.

Battery compartment covers shall be open to dissipate heat.

Battery vent caps shall be maintained and functional.

If required, acid shall be poured into water, water shall not be poured into acid.

Tools and other metallic objects shall be kept away from the top of uncovered batteries.

Batteries shall be properly positioned and secured in powered industrial trucks.

Powered industrial trucks shall be equipped with auxiliary directional lighting, if operated in areas where general lighting is less than two lumens per square foot.
Engineering controls shall be developed and maintained to control exhaust emissions in order to maintain concentration levels of carbon monoxide gas below the levels specified in 29 CFR § 1910.1000.
When powered industrial trucks board trucks and/or railcars during loading or unloading operations, the following precautions shall be taken:

The brakes of highway trucks shall be set and wheel chocks placed under the rear wheels.

Fixed jacks shall be used if necessary to support a semitrailer and prevent upending when the trailer is not coupled to a tractor.

Wheel stops or other recognized positive protection shall be provided to prevent railroad cars from moving.

Portable and/or powered dockboards shall be of sufficient construction to support the load imposed on them.

Portable dockboards shall be securely anchored in position before a powered industrial truck shall cross them.

Portable dockboards shall have handholds, or other effective means to permit safe handling.

The flooring of the truck, trailer or railcar shall be checked for breaks and weakness before the powered industrial truck is driven into the truck, trailer or railcar.

1.4.General Rules of Operation

Only trained operators who have current training certification shall be permitted to operate powered industrial trucks and material handling equipment. A seat equipped with a seat belt shall be provided for the operator. Seatbelts shall be worn by all personnel operating or riding on a powered industrial truck.
Powered industrial trucks shall not be driven up to personnel standing in front of a bench or other fixed object.
Personnel shall not stand or pass under the elevated forks of a powered industrial truck, whether loaded or empty.
During operation, arms or legs shall remain inside the running lines of the powered industrial truck and arms and legs shall not be placed between the uprights of the mast.
Special precautions shall apply to powered industrial trucks and material handling equipment that are unattended. Equipment will be considered unattended whenever:

The operator is 25 feet or more away.

The powered industrial truck and/or material handling equipment is not in view.

When equipment is left unattended, the operator shall:

Fully lower the load engaging means.

Put the equipment controls into neutral.

Set the emergency brake.

Turn off power.

Block both drive wheels (if the equipment is parked on an incline).

When the operator of a powered industrial truck is dismounted, but is within 25 feet of the powered industrial truck, which is still in his view, the operator shall have:

Fully lowered the load engaging means.

Put the equipment controls in neutral.

Set the emergency brake.

When operating on elevated docks, platforms or rail cars, the operator shall maintain a safe distance from the edge of the ramps or platforms.
Powered industrial trucks shall not be used for towing or pushing. Operators shall not use powered industrial trucks to open or close rail car doors, unless the truck is equipped with an attachment specifically designed and manufactured for use in the opening and closing of rail car doors. When using a powered industrial truck and the aforementioned attachment to open and/or close rail car doors, the following requirements shall be followed.

The force applied to the rail car door shall be in a direction parallel with the door travel.

The truck operator shall be trained in the use of the door opening attachment.

The truck operator shall maintain a full view of the opening and/or closing operation.

Employees, other than the truck operator, shall stand clear while the rail car door is being opened/closed.

Powered industrial trucks shall only be operated in areas that afford sufficient headroom under overhead installations, lights, pipes, sprinkler systems, etc.
Personnel shall only be lifted by powered industrial trucks and material handling equipment when:

A safety platform is firmly secured to the lifting carriage or forks.

The platform is constructed with an overhead guard sufficient to provide protection from falling objects, which may be encountered.

The operator remains at the controls while an employee is being lifted.

Means shall be provided whereby personnel on the platform can shut off power to the truck.

Fire aisles, access to stairways and fire equipment shall be kept clear.
Powered industrial truck operators shall observe posted plant speed limits.
Powered industrial trucks shall travel at a safe distance, while maintaining approximately three truck lengths from the powered industrial truck ahead.
Powered industrial trucks shall not pass other powered industrial trucks traveling in the same direction at intersections, blind spots or other dangerous locations.
Powered industrial truck operators shall slow down and sound the horn at cross aisles and other locations where vision is obstructed.
Powered industrial truck operators shall look in the direction of travel and keep a clear view of the path of travel. Powered industrial trucks shall travel with the load trailing if the load being carried obstructs forward view.
Powered industrial trucks shall cross railroad tracks diagonally wherever possible.
Powered industrial trucks shall ascend or descend grades slowly. Loaded powered industrial trucks shall be operated with the load upgrade when ascending or descending grades in excess of 10 percent.
Operators shall raise the load and load engaging means only as far as necessary to clear the road surface on all grades
Operators shall observe and obey all traffic patterns, signs and regulations that are applicable to the area in which the powered industrial truck is being operated.
Operators shall operate powered industrial trucks at speeds that will permit the powered industrial truck to stop in a safe manner.
Operators shall reduce speeds on wet and/or slippery surfaces.
Operators shall not run over loose objects on the roadway surface.
Operators shall not engage in stunt driving and horseplay.
Operators shall ensure that the forks are completely in a pallet before lifting the load. Operators shall center and properly stack all loads. Caution shall be exercised when handling off-center loads that cannot be centered.
Operators shall only handle loads that are within the rated capacity of the powered industrial truck, as specified on the load rating plate.
Operators shall include the weight of attachments as part of the load when calculating load capacity of a powered industrial truck.
Operators shall only tilt masts forward with raised load engaging means when:

Picking-up a load.

The load is in a deposit position over a rack or stack.

Operators shall only tilt stacked or tiered loads backward to the point where the load is stabilized.
Maintenance of Powered industrial trucks

Powered industrial truck operators shall examine/inspect powered industrial trucks prior to operation on a daily and/or shift basis.

Pre-operation inspections shall include, but not be limited to the examination of:

Tires.
Horn.
Lights.
Battery.
Controller brakes.
Steering mechanism.
Cooling system.
Leaks in the fuel and hydraulic system.

Lift system, including the forks, chains, cable and limit switches.

The powered industrial truck examination/inspection shall be conducted for the purpose of discovering all conditions which may adversely affect the safe operation of the equipment.
The operator completing the powered industrial truck examination/inspection shall notify the plant manager or his designee upon discovery of any condition that may adversely affect the safe operation of the equipment.
Upon discovery of any defects that affect safety, the plant manager or his designee shall initiate proper actions to correct such defects in a timely manner.
Powered industrial trucks with defects that make continued operation/use hazardous shall be taken out of service, placed in a designated area and tagged “OUT OF SERVICE – DO NOT OPERATE/USE.” This status must be maintained until all repairs are made.
The operator completing the powered industrial truck examination/inspection shall document the findings of the examination on either the form entitled “Powered Industrial Truck – Pre-operation Examination Form – (Gasoline, LPG or Diesel)” or the form entitled “Powered Industrial Truck – Pre-operation Examination Form – (Electric)” (included in this section).

The “Powered Industrial Truck – Pre-operation Examination Form” shall be kept on file at the plant office of each respective operation for which the examination/inspection was completed until such time as repairs necessary to correct all safety defects have been made and for a period of 12 months.

The 12-month retention period shall have a moving window format.

Completed forms from the first month of the moving window shall be purged from the file at the end of month 13. This procedure shall ensure 12 months of records in the file at all times.

No repairs shall be made to powered industrial trucks in Class I, II, and III locations, as defined by 29 CFR § 1910.178.
Management shall designate areas that are free of hazardous environments for the repair of the fuel and ignition systems of powered industrial trucks that involve potential fire hazards. All such repairs shall be completed in these designated areas.
Repairmen shall disconnect the battery prior to beginning repairs to the electrical system of powered industrial trucks.
All lockout tagout procedures (refer to Lockout/Tagout) shall be implemented and followed prior to repairs being made to powered industrial trucks.
All repairs to powered industrial trucks shall be completed using only parts that are equivalent to those used in the original design, with respect to safety.
Powered industrial trucks shall not be altered unless approved by the powered industrial truck manufacturer.
Powered industrial trucks shall not be operated unless mufflers are maintained as specified below:

Water mufflers shall be filled daily or as frequently as is necessary to prevent depletion of the supply of water below 75 percent of the filled capacity.

Mufflers having screens or other parts that may become clogged shall be cleaned.

Powered industrial trucks emitting hazardous sparks or flames from the exhaust system shall immediately be removed from service until the cause for the emission of such sparks and flames has been corrected.
Powered industrial trucks creating a hazardous condition due to operating temperatures which exceed normal operating temperatures shall be removed from service until the cause for the overheating has been corrected.
Powered industrial trucks shall be maintained in a clean condition, free of lint, excess oil and grease to eliminate fire hazards.
Powered industrial trucks shall be shut off when fuel tanks are being filled.
Spillage of oil or fuel shall be carefully washed away or completely evaporated and the fuel tank cap shall be replaced before the engine is restarted.
Training

Employees shall be instructed in:

Operating instructions.

Warnings and safety precautions.

Similarities and differences between a powered industrial truck and an automobile.

Controls and instrumentation.

Power plant operation and maintenance.

Steering and maneuvering.

Visibility.

Fork and attachment adaptation, including limitations.

Powered industrial truck capacities.

Powered industrial truck stability.

Powered industrial truck inspection and maintenance.

Refueling.

Operating limitations.

Instruction shall also include:

Operating surface conditions.

Composition of probable loads.

Load manipulation, stacking and unstacking.

Pedestrian traffic.

Operating environments and associated hazards.

All training shall be a combination of classroom and practical exercises and shall be conducted by a designated person who has the requisite knowledge, training and experience to provide training to operators and judge their competency.
Upon completion of all training requirements, each perspective operator shall be evaluated by the instructor for competency. All perspective operators deemed competent shall be certified as powered industrial truck operators.
Refresher training, including an evaluation of the effectiveness of that training, shall be conducted to ensure that the operator has the knowledge and skills needed to operate the powered industrial truck safely. Refresher training in relevanttopics shall be provided to the operator when:

1.The operator has been observed to operate the vehicle in an unsafe manner