**Fork Lift Safety**

***Purpose***

**Material handling is a significant safety concern.** During the
movement of products and materials there are numerous opportunities for
personal injury and property damage if proper procedures and caution are
not used. This chapter applies to all powered industrial tucks, hoists &
lifting gear. The information in this chapter shall be used to train
prospective industrial truck operators and provide the basis for
refresher and annual retraining. OSHA reference for Powered Industrial
Trucks is 1910.178.

***Pre-Qualifications for Powered Industrial Truck (PIT) Operators***

All candidates for PIT operators must meet the following basic
requirements prior to starting initial or annual training:

1.  Must have no adverse vision problems that cannot be corrected by
    glasses or contacts

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1.  No adverse hearing loss that cannot be corrected with hearing aids

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1.  No physical impairments that would impair safe operation of the PIT

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1.  No neurological disorders that affect balance or consciousness

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1.  Not taking any medication that affects perception, vision, or
    physical abilities

***Training***

**Training for Powered Industrial Truck (PIT) Operators** shall be
conducted by an experienced operator, selected by Management. All
operational training shall be conducted under close supervision. All
training and evaluation must be completed before an operator is
permitted to use a Powered Industrial Truck (forklift, etc) without
continual & close supervision.  Training consists of:

**Trainees may operate a powered industrial truck only:**

1.  Under the direct supervision of persons, selected by management, who
    have the knowledge, training, and experience to train operators and
    evaluate their competence; and

2.  Where such operation does not endanger the trainee or other
    employees.

**Training Content**

Training consists of a combination of formal instruction, practical
training (demonstrations performed by the trainer and practical
exercises performed by the trainee), and evaluation of the operator\'s
performance in the workplace.

**Initial Training:** Powered industrial truck operators shall receive
initial training in the following topics:

**Truck-related training topics:**

1.  Operating instructions, warnings, and precautions for the types of
    truck the operator will be authorized to operate

2.  Differences between the truck and the automobile

3.  Truck controls and instrumentation: where they are located, what
    they do, and how they work

4.  Engine or motor operation

5.  Steering and maneuvering

6.  Visibility (including restrictions due to loading)

7.  Fork and attachment adaptation, operation, and use limitations

8.  Vehicle capacity

9.  Vehicle stability

10. Any vehicle inspection and maintenance that the operator will be
    required to perform

11. Refueling and/or charging and recharging of batteries

12. Operating limitations

13. Any other operating instructions, warnings, or precautions listed in
    the operator\'s manual for the types of vehicle that the employee is
    being trained to operate.

**Workplace-related topics**:

1.  Surface conditions where the vehicle will be operated

2.  Composition of loads to be carried and load stability

3.  Load manipulation, stacking, and unstacking

4.  Pedestrian traffic in areas where the vehicle will be operated

5.  Narrow aisles and other restricted places where the vehicle will be
    operated

6.  Hazardous (classified) locations where the vehicle will be operated

7.  Ramps and other sloped surfaces that could affect the vehicle\'s
    stability

8.  Closed environments and other areas where insufficient ventilation
    or poor vehicle maintenance could cause a buildup of carbon monoxide
    or diesel exhaust

9.  Other unique or potentially hazardous environmental conditions in
    the workplace that could affect safe operation

**Refresher training and evaluation. ** 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 relevant
topics shall be provided to the operator when:

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

2.  The operator has been involved in an accident or near-miss incident

3.  The operator has received an evaluation that reveals that the
    operator is not operating the truck safely

4.  The operator is assigned to drive a different type of truck

5.  A condition in the workplace changes in a manner that could affect
    safe operation of the truck

6.  Once every 3 years an evaluation will be conducted of each powered
    industrial truck operator\'s performance.

 

***Safe Operating Procedures (SOP) & Rules***

1.  Only authorized and trained personnel will operate PITs.

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1.  All PITs will be equipped with a headache rack, fire extinguisher,
    rotating beacon, back-up alarm and seat belts. Seat belts will be
    worn at all times by the Operator.

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1.  The operator will perform daily pre- and post-trip inspections.

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1.  Any safety defects (such as hydraulic fluid leaks; defective brakes,
    steering, lights, or horn; and/or missing fire extinguisher, lights,
    seat belt, or back-up alarm) will be reported for immediate repair
    or have the PIT taken \"Out of Service\".

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1.  Operators will follow the proper recharging or refueling safety
    procedures.

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1.  Loads will be tilted back and carried no more than 6 inches from the
    ground. Loads that restrict the operator\'s vision will be
    transported backwards.

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1.  PITs will travel no faster than 5 mph or faster than a normal walk.

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1.  Hard hats will be worn by PIT Operators in high lift areas. .

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1.  Operator will sound horn and use extreme caution when meeting
    pedestrians, making turns and cornering.

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1.  Passengers may not ride on any portion of a PIT. Only the operator
    will ride PITs. \"NO PASSENGERS\" decals will be affixed on all
    PITs.

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1.  If PITs are used as a man lift, an appropriate man lift platform
    (cage with standard rails and toe-boards) will be used.

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1.  Aisle will be maintained free from obstructions, marked and wide
    enough (six foot minimum) for vehicle operation.

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1.  Lift capacity will be marked on all PITs. Operator will assure load
    does not exceed rated weight limits.

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1.  When un-attended, PITs will be turned off, forks lowered to the
    ground and parking brake applied.

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1.  All PITs (with exception of pallet jacks) will be equipped with a
    multi-purpose dry chemical fire extinguisher. (Minimum rating;
    2A:10B:C)

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1.  Operators are instructed to report all accidents, regardless of
    fault and severity, to Management. Management will conduct an
    accident investigation.

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1.  When loading rail cars and trailers, dock plates will be used.
    Operators will assure dock plates are in good condition and will
    store on edge when not in use.

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1.  Rail cars and trailers will be parked squarely to the loading area
    and have wheels chocked in place. Operators will follow established
    Docking/Un-Docking Procedures.

***Changing and Charging Storage Batteries.***

1.  Battery charging installations shall be located in areas designated
    for that purpose.

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1.  Facilities shall 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.

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1.  A conveyor, overhead hoist, or equivalent material handling
    equipment shall be provided for handling batteries.

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1.  Reinstalled batteries shall be properly positioned and secured in
    the truck.

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1.  A carboy tilter or siphon shall be provided for handling
    electrolyte.

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1.  When charging batteries, acid shall be poured into water; water
    shall not be poured into acid.

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1.  Trucks shall be properly positioned and brake applied before
    attempting to change or charge batteries.

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1.  Care shall be taken to assure that vent caps are functioning. The
    battery (or compartment) cover(s) shall be open to dissipate heat.

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1.  Smoking is prohibited in the charging area.

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1.  Precautions shall be taken to prevent open flames, sparks, or
    electric arcs in battery charging areas.

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

***Trucks and Trailers.***

1.  The flooring of trucks and trailers shall be checked for breaks and
    weakness before they are driven onto.

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1.  The brakes of highway trucks shall be set and wheel chocks placed
    under the rear wheels to prevent the trucks from rolling while they
    are boarded with powered industrial trucks.

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1.  Wheel stops or other recognized positive protection shall be
    provided to prevent railroad cars from moving during loading or
    unloading operations.

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1.  Fixed jacks may be necessary to support a semitrailer and prevent
    upending during the loading or unloading when the trailer is not
    coupled to a tractor.

***Operations***

1.  If at any time a powered industrial truck is found to be in need of
    repair, defective, or in any way unsafe, the truck shall be taken
    out of service until it has been restored to safe operating
    condition.

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1.  Trucks shall not be driven up to anyone standing in front of a bench
    or other fixed object.

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1.  No person shall be allowed to stand or pass under the elevated
    portion of any truck, whether loaded or empty.

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1.  Unauthorized personnel shall not be permitted to ride on powered
    industrial trucks.

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1.  Arms or Legs shall not be placed between the uprights of the mast or
    outside the running lines of the truck.

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1.  When a powered industrial truck is left unattended, load engaging
    means shall be fully lowered, controls shall be neutralized, power
    shall be shut off, and brakes set. Wheels shall be blocked if the
    truck is parked on an incline.

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1.  A safe distance shall be maintained from the edge of ramps or
    platforms while on any elevated dock, or platform or freight car.
    Trucks shall not be used for opening or closing freight doors.

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1.  There shall be sufficient headroom under overhead installations,
    lights, pipes, sprinkler system, etc.

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1.  An overhead guard shall be used as protection against falling
    objects. It should be noted that an overhead guard is intended to
    offer protection from the impact of small packages, boxes, bagged
    material, etc., representative of the job application, but not to
    withstand the impact of a falling capacity load.

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1.  A load backrest extension shall be used whenever necessary to
    minimize the possibility of the load or part of it from falling
    rearward.

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1.  Trucks shall not be parked so as to block fire aisles, access to
    stairways, or fire equipment.

***Traveling***

1.  All traffic regulations shall be observed, including authorized
    speed limits. A safe distance shall be maintained approximately
    three truck lengths from the truck ahead, and the truck shall be
    kept under control at all times.

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1.  The right of way shall be yielded to ambulances, fire trucks, or
    other vehicles in emergency situations.

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1.  Other trucks traveling in the same direction at intersections, blind
    spots, or other dangerous locations shall not be passed.

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1.  The driver shall be required to slow down and sound the horn at
    cross aisles and other locations where vision is obstructed. If the
    load being carried obstructs forward view, the driver shall be
    required to travel with the load trailing.

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1.  The driver shall be required to look in the direction of, and keep a
    clear view of the path of travel.

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1.  Grades shall be ascended or descended slowly. When ascending or
    descending grades in excess of 10 percent, loaded trucks shall be
    driven with the load upgrade. On all grades the load and load
    engaging means shall be tilted back if applicable, and raised only
    as far as necessary to clear the road surface.

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1.  Under all travel conditions the truck shall be operated at a speed
    that will permit it to be brought to a stop in a safe manner.

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1.  Stunt driving and horseplay shall not be permitted.

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1.  The driver shall be required to slow down for wet and slippery
    floors.

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1.  Dockboard or bridgeplates, shall be properly secured before they are
    driven over. Dockboard or bridgeplates shall be driven over
    carefully and slowly and their rated capacity never exceeded.

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1.  Running over loose objects on the roadway surface shall be avoided.

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1.  While negotiating turns, speed shall be reduced to a safe level by
    means of turning the hand steering wheel in a smooth, sweeping
    motion. Except when maneuvering at a very low speed, the hand
    steering wheel shall be turned at a moderate, even rate.

***Loading.***

1.  Only stable or safely arranged loads shall be handled. Caution shall
    be exercised when handling off-center loads which cannot be
    centered.

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1.  Only loads within the rated capacity of the truck shall be handled.

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1.  The long or high (including multiple-tiered) loads which may affect
    capacity shall be adjusted.

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1.  Trucks equipped with attachments shall be operated as partially
    loaded trucks when not handling a load.

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1.  A load engaging means shall be placed under the load as far as
    possible; the mast shall be carefully tilted backward to stabilize
    the load.

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1.  Extreme care shall be used when tilting the load forward or
    backward, particularly when high tiering. Tilting forward with load
    engaging means elevated shall be 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, only enough backward tilt to stabilize the load shall be
    used.

***Fueling Safety***

1.  Fuel tanks shall not be filled while the engine is running. Spillage
    shall be avoided.

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1.  Spillage of oil or fuel shall be carefully washed away or completely
    evaporated and the fuel tank cap replaced before restarting engine.

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1.  No truck shall be operated with a leak in the fuel system until the
    leak has been corrected.

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1.  Open flames shall not be used for checking electrolyte level in
    storage batteries or gasoline level in fuel tanks.

***Maintenance of Powered Industrial Trucks.***

1.  Any power-operated industrial truck not in safe operating condition
    shall be removed from service. All repairs shall be made by
    authorized personnel.

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1.  Those repairs to the fuel and ignition systems of industrial trucks
    which involve fire hazards shall be conducted only in locations
    designated for such repairs.

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1.  Trucks in need of repairs to the electrical system shall have the
    battery disconnected prior to such repairs.

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1.  All parts of any such industrial truck requiring replacement shall
    be replaced only by parts equivalent as to safety with those used in
    the original design.

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1.  Industrial trucks shall not be altered so that the relative
    positions of the various parts are different from what they were
    when originally received from the manufacturer, nor shall they be
    altered either by the addition of extra parts not provided by the
    manufacturer or by the elimination of any parts. Additional
    counter-weighting of fork trucks shall not be done unless approved
    by the truck manufacturer.

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1.  Industrial trucks shall be examined before being placed in service,
    and shall not be placed in service if the examination shows any
    condition adversely affecting the safety of the vehicle. Such
    examination shall be made at least daily. Where industrial trucks
    are used on a round-the-clock basis, they shall be examined prior to
    use each shift. Defects when found shall be immediately reported and
    corrected.

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1.  When the temperature of any part of any truck is found to be in
    excess of its normal operating temperature, thus creating a
    hazardous condition, the vehicle shall be removed from service and
    not returned to service until the cause for such overheating has
    been eliminated.

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1.  Industrial trucks shall be kept in a clean condition, free of lint,
    excess oil, and grease. Noncombustible agents should be used for
    cleaning trucks. Low flash point (below 100 deg. F.) solvents shall
    not be used. High flash point (at or above 100 deg. F.) solvents may
    be used.

***Safe Operation Procedure for Charging LPG Tank***

> 1\. No Smoking.
>
> 2\. Move LPG PIT outside for refueling.
>
> 3\. Turn off PIT.
>
> 4\. LPG tanks will be removed in the following order:
>
> -shut off service valve
>
> -disconnect tank from hose
>
> -unbuckle and remove tank from bracket
>
> 5\. LPG tanks will be replaced in to following order:
>
> -place tank in bracket and re-buckle
>
> -reconnect hose to tank and tighten firmly
>
> -open valve slowly and assure proper seal

**NOTE:** Federal Law Prohibits dispensing an improper fuel type into
any Vehicle or into a non-approved fuel container.

**[In Case of LPG Leaks or Tank Rupture]{.underline}**

> 1\. DO NOT start or move the PIT.
>
> 2\. If fuel hose is leaking, Close valve immediately and
>
> place PIT \"Out of Service\" until repaired.
>
> 3\. If tank ruptures, warn other, immediately leave the area (at least
> 50 feet) and notify Management. Do not re-enter the area until cleared
> by Management.

***Powered Industrial Truck Pre-Use Checklist***

***A check of the following items (as applicable) is to be conducted by
the operator prior to use each shift.***

> Lights
>
> Horn
>
> Brakes
>
> Leaks
>
> Warning Beacon
>
> Backup Warning Alarm
>
> Fire Extinguisher

If any deficiencies are noted, the unit is to be placed OUT OF SERVICE
until the problem has been corrected. Additionally, it is the operators
responsibility to notify the immediate supervisor and fill out a
maintenance request.