safety procedure: powered industrial truck

Safety Procedure: Powered Industrial Truck

I. PURPOSE

A. This procedure establishes procedures for the safe operation and maintenance ofpowered industrial trucks (forklifts) by City of Corona employees at all Cityfacilities. These procedures establish uniform requirements designed to ensurethat forklift safety training, operations, inspection, and maintenance practices arecommunicated to and understood by the affected employees.

II. SCOPE

A. This procedure applies to all employees assigned to operate powered industrialtrucks. The City operates: sit down counter balance forklift, narrow aisle lift truck,and powered pallet jacks.

III. REGULATORY REFERENCES

A. CCR Title 8, Ch.4, Subch.7, Art.25, Sections 3649, 3650, 3653, 3658 – 3664, and3668. ANSI/ASME B56.1

IV. RESPONSIBLITIES

A. City

1. The City of Corona is responsible to purchase powered industrial trucks thatmeet ANSI/ASME standards and maintain them in a safe, serviceable condition.The City shall post and enforce the California Operator Safety Rules.(Attachment A)

B. Human Resources / Safety Division

1. Human Resources has the overall responsibility to provide training, evaluation,and certification of all powered industrial truck operators in accordance with theapplicable California Code of Regulations. They will also maintain trainingrecords and update this procedure as necessary.

C. Supervisors

1. Supervisors are responsible to enforce the requirements and procedures of thisprocedure.

a. They shall ensure that the assigned operators conduct and document thepre-shift inspections prior to using powered industrial trucks and respond toreports of discrepancies. They shall observe the daily operations forprocedure compliance and recommend retraining and evaluation asnecessary.

Powered Industrial Truck - Forklifts

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D. Forklift Operators1. Operators are responsible to follow the safe operating rules of this procedure at

all times. They shall perform and log pre-operational equipment inspections onall powered industrial trucks prior to using that truck. They shall immediatelyreport any malfunctions to their supervisor or fleet maintenance and the vehicleshall not be put into service until it is made safe. All accidents or near missesmust be reported to their supervisors immediately.

V. Definitions

A. Approved Truck or Industrial Truck - A truck that is listed or approved for firesafety purposes for the intended use by a nationally recognized testing laboratoryusing nationally recognized testing standards.

B. ASAE - American Society of Agriculture Engineers.

C. Canopy (Overhead Guard) - An overhead protection or shield which covers thetruck operator in a manner that will minimize the possibility of injury from fallingobjects.

D. Center of Gravity - The point on an object at which all of the object’s weight isconnected. For symmetrical loads, the center of gravity is at the middle of theload.

E. Counterweight - The weight that is built into the truck’s basic structure and is usedto offset the load’s weight and to maximize the vehicle’s resistance to tipping over.

F. Fulcrum - The truck’s point of balance when it tips over.

G. Grade - the slope of a surface, which is usually measured as the number of feet ofrise or fall over a hundred foot horizontal distance (the slope is expressed as apercent).

H. High-Lift Truck - An industrial truck equipped with a power-operated lifting deviceused for the transportation, tiering and positioning of loads. As used in thisdefinition, high-lift trucks include riderless high-lift straddle trucks where theemployee operates the truck using a moveable steering arm and control handlewhile standing or walking behind the truck. (Excluded are front-end loaders andtiering conveyors).

I. Industrial Truck - A mobile power-driven truck used for hauling, pushing, lifting, ortiering materials where normal work is normally confined within the boundaries ofa place of employment. As used in this definition, industrial trucks includeunmanned automated or semi-automated transport vehicles which utilize wheelsand run on guide rails or narrow gauge rail tracks and can be operated by eitherremote control (i.e. a hand held pendant) or radio communication.

J. Lateral stability - is a truck’s resistance to overturning sideways.

K. Line of action - is an imaginary vertical line through an object’s center of gravity.


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L. Load center - is the horizontal distance from the load’s edge (or the fork’s or otherattachment’s vertical face) to the line of action through the load’s center of gravity.

M. Longitudinal stability – is the truck’s resistance to overturning forward or rearward.

N. Moment - is the product of the object’s weight times the distance from a fixed point(usually the fulcrum). In case of a powered industrial truck, the distance ismeasured from the point at which the truck will tip over to the object’s line ofaction. The distance is always measured perpendicular to the line of action.

O. Rider Truck – an industrial truck designed to be controlled by a riding operator.

P. ROPS - Rollover protective structure (including protective frames and protectiveenclosures).

Q. SAE - Society of Automotive Engineers.

R. Track - is the distance between the wheels on the same axle of the truck.

S. Wheelbase - is the distance between the centerline of the vehicle’s front and rearwheels.

T. Elevating Work Platform - is a manufactures approved work platform.

U. Lock-out / Tag-out - The power source shall be de-energized or disengaged.

VI. Safe Operating Rules

A. Lift trucks shall be operated in a safe manner in accordance with the followingrules:

1. Only drivers trained and authorized by the City of Corona in the safe operationof lift trucks shall be permitted to operate such vehicles.

2. Securely fasten your seat belt at all times.

3. Employee must wear a hardhat.

4. Stunt driving and horseplay are prohibited.

5. No riders shall be permitted on forklifts.

6. Employees shall not ride on the forks of lift trucks.

7. Employees shall not place any part of their bodies outside the running lines ofa forklift truck or between mast uprights or other parts of the truck where shearor crushing hazards exist.


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8. Employees shall not be allowed to stand, pass, or work under the elevatedportion of any forklift, loaded or empty, unless it is effectively blocked to preventit from falling.

9. Drivers shall inspect the truck at the beginning of each shift, and if it is found tobe unsafe, the matter shall be reported immediately to their supervisor or fleetmaintenance and the vehicle shall not be put in service again until it has beenmade safe. Attention shall be given to the proper functioning of tires, horn,lights, battery, controller, brakes, steering mechanism, cooling system, and thelift system for forklifts (forks, chains, cable, and limit switches).

10. No truck shall be operated with a leak in the fuel system.

11. Trucks shall not exceed the authorized or safe speed, always maintaining asafe distance from other vehicles, keeping the forklift under positive control atall times and all established traffic regulations shall be observed. For forkliftstraveling in the same direction, a safe distance may be considered to beapproximately 3 truck lengths or preferably a time lapse-3 seconds-passing thesame point.

12. Trucks traveling in the same direction shall not be passed at intersections, blindspots, or dangerous locations.

13. The driver shall slow down and sound the horn at cross aisles and the otherlocations where vision is obstructed. If the load being carried obstructs forwardview, the driver shall be required to travel with the load trailing.

14. Operators shall look in the direction of travel and shall not move a vehicle untilcertain that all persons are in the clear.

15. Vehicles shall not be driven up to anyone standing in front of a bench or otherfixed object of such size that the person could be caught between the forkliftand object.

16. Grades shall be ascended or descended slowly, with the load upgrade.

17. The forks shall always be carried as low as possible, consistent with safeoperations.

18. When leaving a vehicle unattended (the operator is over 25 feet from or out ofsight of the industrial truck) the brakes shall be set, the mast is brought to thevertical position, and forks left in the down position.

19. When the operator of a forklift truck is dismounted and within 25 feet of thetruck which remains in the operator’s view, the forklifts shall be fully lowered,controls placed in neutral, and the brakes set to prevent movement.Exceptions – Forks on fork-equipped lift trucks may be in the raised position forloading and unloading if the forks are raised no more than 42 inches above thelevel where the operator/ loaders are standing and the power is shut off,


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controls placed in neutral and the brakes set. If on an incline, the wheels shallbe blocked.

20. Forklifts shall not be operated on floors, sidewalks doors, or platforms that willnot safely support the load.

21. Prior to driving onto trucks, and trailers, their flooring shall be inspected forbreaks and other structural weaknesses.

22. Forklifts shall not be driven in and out of trucks or trailers at loading docks untilsuch trucks or trailers are securely blocked or restrained and the brakes set.

23. Forklifts shall not be loaded in excess of their rated capacity.

24. A loaded forklift shall not be moved until the load is safe and secure.

25. Extreme care shall be taken when tilting loads. Tilting forward with the loadelevated shall be prohibited except when picking up a load. Elevated loadsshall not be tilted forward except when the load is being deposited onto astorage rack or equivalent. When stacking or tiering, backward tilt shall belimited to that necessary to stabilize the load.

26. The load engaging device shall be placed in such a manner that the load will besecurely held or supported. Forks will have a minimum 2/3 engagement.

27. Special precautions shall be taken in the securing and handling of loads byforklifts equipped with attachments, during the operation of these trucks afterthe loads have been removed.

28. When elevating employees the platform shall be of sufficient size, platform shallbe secured to the forks or mast and meet the guardrail and toe boardrequirements, the platform floor shall have no spaces or holes greater than oneinch and have a slip resistant surface.

VII. Pre-Operational Inspection Procedures

A. Operators must perform a pre-operational equipment inspection on poweredindustrial trucks at the beginning of each shift. Attention shall be given to theproper functioning of the tires, horn, lights, battery, controller, brakes, steering,cooling system, guards, and the lift system (forks, chains, rails, rollers, andhydraulics). All discrepancies are to be immediately reported to their supervisor orFleet Maintenance. The truck shall not be put in service until the discrepancies arecorrected and the truck is made safe. The inspection results and records ofmaintenance will be retained with the truck or in near enough proximity to allowreview of the records as part of the next inspection. (Attachment B)

VIII. Maintenance of Powered Industrial Trucks (Forklifts)

A. The following maintenance safety procedures shall be followed:


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1. Forklift repair operations involving open flames or which may produce sparks orother sources of ignition shall not be performed in Class I, II and III locations,unless and until tests show that atmospheric concentration of flammable orcombustible vapors do not exceed 20 percent L.E.L. of such flammable orcombustible materials and until precautions are taken to maintain theatmosphere at or below 20 percent L.E.L. Such precautions could include, butnot limited to removal of flammable material.

2. Forklift trucks shall be kept in a clean condition free of debris, oil, and grease.

3. Batteries on all forklifts shall be disconnected during repairs to the primaryelectrical system unless power is necessary for testing and repair. Trucksequipped with systems capable of storing residual energy shall be safelydischarged before work on the primary electrical system begins.

4. All replacement parts for forklifts shall be equivalent in safety to the originalparts.

B. Procedure for Changing LPG Tanks

1. No smoking

2. Wear required Personal Protective Equipment (goggles, face shield, apron,gloves, etc.) prior to changing.

3. Move LPG forklift truck outside for tank changing.

4. Forklift should run until it stalls.

5. Turn forklift off.

a. LPG tanks will be removed in the following order:

i. Shut off service valve.

ii. Disconnect tank from hose.

iii. Unbuckle and remove tank from bracket.

b. LPG tanks will be replaced in the following order:

i. Place tank in bracket and re-buckle.

ii. Reconnect hose to tank and tighten firmly.

iii. Open valve slowly and assure proper seal.

c. In Case of LPG Leaks or Tank Rupture:

i. DO NOT start or move the forklift;


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ii. If fuel hose is leaking, close the tank valve immediately, if it is safe to doso.

iii. Tag the forklift “Out of Service” and report it to your supervisor and donot use until repaired.

iv. If tank ruptures, warn others, immediately leave the area (at least 50 feetaway) and notify your supervisor or management. CALL-911.

v. DO NOT re-enter the area until cleared by your supervisor ormanagement.

C. Refueling Diesel-Powered Forklifts

1. Smoking while refueling is prohibited at all times.

2. Diesel powered forklifts shall be fueled in designated areas.

3. The fueling area shall be free from excessive heat, open flames and sparks.

D. Inspecting, Changing and Charging Storage Batteries

1. The following procedures shall be followed while inspecting, changing orcharging storage batteries:

a. Employee must wear required Personal Protective Equipment (safetygoggles, butyl gloves must be worn when opening battery caps to inspectfluid levels) (safety goggles, butyl gloves, a face shield and apron w/sleevesmust be worn when filling batteries).

b. Battery charging installation shall be located in areas designated for thatpurpose. Chargers must be kept away from heat, flames, and other ignitionsources; chargers must be located in an open area, where there is good airmovement to remove hydrogen gas, which can be released duringcharging; a “No Smoking’’ sign must be posted; a fire extinguisher must belocated nearby; and an emergency eyewash station must be within 10seconds or 55 feet.

c. Facility shall be provided for flushing and neutralizing spilled electrolyte, forfire protection, for protecting charging apparatus from damage by trucks,and for adequate ventilation for dispersal of fumes from gassing batteries.

d. A conveyor, overhead hoist, or equivalent material handling equipmentshall be provided for handling batteries.

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

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


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

h. Trucks shall be properly positioned and brake applied before attempting tochange or charge batteries.

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

j. Smoking shall be prohibited in the charging area.

k. Precautions shall be taken to prevent open flames, sparks, or electric arcsin battery charging areas.

l. Tools and other metallic objects shall be kept away from the top ofuncovered batteries. Metallic objects are not to be worn when inspecting,changing or charging batteries (remove wrist watches, rings, ear rings,etc.).

IX. Training

A. Powered industrial truck operators are to receive initial training in the followingtopics:

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

2. Differences between the truck and automobile.

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

4. Engine or motor operation.

5. Steering and maneuvering.

6. Visibility (including restrictions due to loading).

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

8. Vehicle capacity.

9. Vehicle stability.

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

11. Refueling and/or charging of batteries.


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12. Operating limitations; and any other operating instructions, warning, orprecautions listed in the operator’s manual for the types of vehicle that theemployee is being trained to operate.

B. Work Related Topics

1. Surface conditions where the vehicle will be operated.

2. Compositions of loads to be carried and load stability.

3. Load manipulation, stacking, and un-stacking.

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 poorvehicle maintenance could cause a build-up of carbon monoxide or dieselexhaust.

X. Refresher Training

A. Refresher training will be required for an operator when the following is observedby the employee’s performance:

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.

3. The operator has received an evaluation that reveals the operator is notoperating 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 safeoperation of the truck.

XI. Three Year Evaluation

A. An evaluation of each forklift operator’s performance shall be conducted at leastonce every three years. If the evaluation shows that the operator is lacking theappropriate skills and knowledge the operator will be retrained.

XII. Procedure Availability


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A. The City of Corona Powered Industrial Truck (Forklifts) Procedure will be madeavailable to all City of Corona employees, their designated representatives, andDivision of Occupational Safety and Health upon request. The Policy is located atthe Safety Division office located at: City Hall, 400 S. Vicentia Avenue, CoronaCA 92882 and on the InfoWeb.

XIII. Attachments

A. Attachment A – Cal/OSHA Operating Rules for Industrial Trucks

B. Attachment B – Pre-Operational Inspection

1. Sit Down Counter Balance2. Narrow Aisle3. Electric Pallet Jack

C. Attachment C – Powered Industrial Truck Operator Evaluation


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Attachment – A


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Attachment – B1

Instruction:

Operating Controls (Operational) Date Date Date Date Date Date Date Date Date Date

Emergency Stop & Brakes

Operation Levers & Controls

Steering Mechanism

Hydraulic Leaks

Forks

Extension Cylinders & Chains

Electrical Lines

Vertical Mast Sliding & Rolling Parts

Base (Visual)

Broken, Cracked or Loose Parts

Lights, Mirrors & Windows Clean

Seat Belt & It's Mounts

Safety Signs & Data Plate

Tires

Hour Meter

Horn & Back Up Alarm

Gauges/Instruments

Owner's Manual

Engine Compartment (Visual)

Oil Level

Belt, Hose & Motor Condition

Battery & Electrical

Obvious Damage or Leaks

MAST & FORKS

Each forklift will be operationally tested and visually inspected each day. The designated inspector will place a () in the appropriate box when an

item passes inspection. Leave the box empty and note a brief description of any problem. Immediately notify your supervisor of any deficiencies.

Signature

PRE-OPERATIONAL FORKLIFT INSPECTION FORM

COUNTER BALANCE

Li ft Name and/or Number:


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Attachment – B2

Instruction:


Horn & Back Up Alarm

Steering Mechanism

Direction/Speed Control

Lift/Lower System

Brake

Deadman brake

Hydraulic leaks

Forks

Extension Cylidners and Chains

Electrical Lines

Vert Mast Sliding & Rolling Parts

Base (Visual)


Lights & Mirrors

Hour Meter

Safety Signs Data Plate

Tires

Gauges/Instruments

Operator's Manual


Oil Level

Belt, Hose & Motor Condition



Mast & Forks

Li ft Name and/or Number


NARROW AISLE

Each forklift will be operationally tested and visually inspected each day. The designated inspector will place a () in the appropriate box when an

item passes inspection. Leave the box emty and not a brief description of any problem. Immediately notify your supervisor of any deficiencies.

Signature


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Attachment – B3

Instruction:


Horn

Drive Control - Forward/Reverse

Direction/Speed Control

Hoist/Lowering Control

Deadman Brake

Base (Visual)


Lights & Alarms (where present)

Forks

Tires

Hand Guards

Safety Signs & Data Plate

Gauges/Instruments

Hour Meter

Operator's Manual




Signature


PALLET JACK

Lift Name and/or Number:

Each pallet jack will be operationally tested and visually inspected each day. The designated inspector will place a () in the appropriate box when

an item passes inspection. Leave the box empty and note a brief description of any problem. Immediately notify your supervisor of any deficiencies.


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Attachment – C

PASS FAIL

COUNTER BALANCE

YES NO N/A

Did the operator complete a pre-use inspection of the PIT?

Did the operator conduct a visual inspection of the work area?

Did the operator conducat a visual inspection of the load?

Did the operator adjust the forks to the proper distance for the load?

Did the operator determine the weight of the load prior to the lift?

Did the operator inspect the floor of the trailer?

Are the trailer brakes locked and wheels chocked?

Did the operator insepct the dock boards / bridge plates?

Did the operator use the seat belt?

YES NO N/A

Did the operator show familiarity with the PIT controls?

Did the operator approach the load at a safe rate of speed?

Did the operator strike anything as he/she attempted to position the forks under the load?

Are the forks under the entire load?

Is the load properly balanced?

Did the operator raise and tilt the load properly?

Did the operator lower the load to 6" from the ground prior to traveling?

Did the operator travel with the load at a safe rate of speed, under control, within the designated aisle?

Did the operator travel in reverse when his/her vision was obstructed?

Did the operator yield to pedestrians?

Did the operator slow down and use the horn at intersections?

Did the operator properly turn the corner(s) and was aware of the rear end swing?

Did the operator drive up and down the ramp or other incline properly?

Did the operator look behind when backing up?

Did the operator stop the PIT in a smooth manner?

Did the operator lower the load and place it in the proper location?

YES NO N/A

Did the operator come to a complete stop before turning off the PIT?

Did the operator place the forks flat on the floor when parking?

Did the operator place the controls in neutral when parking the PIT?

Did the operator set the parking brake when parking the PIT?

Did the operator turn off the power when parking the PIT?

Did the operator close the valve of the propane cylinder?

Operator's Signature: _____________________ Evaluator's Signature: ____________________ Date: _________

Notes:

POWERED INDUSTRIAL TRUCK OPERATOR EVALUATION

ROUGH TERRAIN

Each PIT Operator is required to be evaluated by a competent person prior to their initial use and once every

three (3) years thereafter. If the evaluator believes that the operator's skills are inadequate, additional training

may be required. This evaluation is valid only for type of PIT noted above.

Pre-operation of the PIT

Operation of PIT

Post-operation of the PIT

DEPARTMENT: _______________________

DATE: _____________________

PALLET JACKNARROW AISLE

PIT MODEL:

NAME OF OPERATOR: ________________________

NAME OF EVALUATOR: _______________________

safety procedure: powered industrial truck

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