Control, Safe Use and Operation of Forklift Trucks and Sideloaders British Railways Board
Page 1 of 12 Part A Synopsis A standard detailing the requirements for control, safe use and operation of forklift trucks and side loaders. Approval and authorisation Signatures removed from electronic version Submitted by: Approved by : Nominated responsible manager Chairman, Civil Engineering Subject Committee Approved by : Chairman, Electrification & Plant Subject Committee Authorised by : Board Member, Engineering Control, Safe Use and Operation of Forklift Trucks and Side loaders This document is the property of the, it shall not be reproduced in whole or in part, nor disclosed to a third party, without the written permission of the Director, Engineering Standards. Copyright 1994 Published By s Macmillan House Paddington
Page 2 of 12 Issue / Revision record
Page 3 of 12 This standard will be updated when necessary by distribution of a complete replacement. Amended or additional parts of revised pages will be marked by a vertical black line in the adjacent margin. Issue Rev Date Comments 1 A Feb. 94 Replaces the sections relating to forklift trucks in Part 7 of the Working Manual dated Feb. 1986. Responsibilities and distribution To all managers responsible for the operation and use of forklift trucks and side loaders on railway operational land. Implementation This Group standard is mandatory and the process of implementation shall begin on its receipt. Supply Controlled and uncontrolled copies of this standard may be obtained from the TDCC Manager, Document Services, Railway Technical Centre, London Road, Derby, DE24 8UP. Contents Section Description Page No. Part A Synopsis 1 Approval & authorisation 1 Issue/Revision record 2 Responsibilities and distribution 2 Implementation 2 Supply 2 Contents 2 Part B 1 Purpose 3 2 Scope 3 3 Key definitions 3 4 Acquisition 4 5 Registration 4 6 Maintenance 5 7 Modifications 6 8 Statutory Requirements 6 9 Training and Authorisation 6 10 Safe Systems of Work 8 11 Personal Protective Equipment 11 12 Related References 11
Page 4 of 12 Part B 1 Purpose To specify to managers, supervisors and operators, factors that must be considered for controlling, safely using and operating forklift trucks, telescopic loaders and side loaders in the railway environment. 2 Scope This standard applies to all personnel responsible for the operation of all types of forklift trucks, telescopic loaders and side loaders used in pursuance of railway business on railway property. 3 Key definitions 3.1 Forklift Truck A 3 or 4-wheeled counterbalanced powered truck, with the driver standing or seated on the truck, which is fitted with a mast which may be telescopic. Forks of various lengths may be attached to a carriage on the mast which can be raised and lowered within the limits of the mast design. The mast, together with the forks is, generally, designed to tilt forwards or backwards. For the purposes of this standard the term forklift truck will include telescopic loaders. 3.2 Side loader A wheeled vehicle carrying a mast, which may be telescopic with a sliding carriage and forks capable of being raised and lowered. The whole mast assembly is arranged at right angles to the normal line of travel and is capable of moving across the vehicle, thus presenting the forks at the side. The load is carried on a platform during movement. Some designs make provision for both longitudinal and transverse motion of the truck. 3.3 Vehicle For the purpose of this standard this term refers to forklift trucks, telescopic loaders and side loaders.
Page 5 of 12 4 Acquisition Vehicles must comply with the Council of European Community's Directives 86/663 & 89/240 which are absolute minimum requirements. Other requirements are as listed in this section, British Standard Specifications and International Standard Specifications. Where a conflict occurs then requirements shall have precedence in the order quoted above. Vehicles must have suitable stability characteristics for the ground conditions where they are to be used. Vehicles equipped with a telescopic boom which allows variable reach working, must be provided with the following :- A legible duty table showing tabulated values of load and reach prominently displayed in the cab, for operator use and externally on both sides of the vehicle structure for supervisor use. A mechanical type load/reach indicator which is visible to the operator and the supervisor from which the duties can be determined. Vehicles acquired for use on station platforms must meet the acquisition requirements specified in GM/OG0007 - Control Safe Use and Operation of Station and Depot Vehicles. 5 Registration All vehicles must be registered so that they can be uniquely identified for maintenance purposes. The person responsible for the vehicle shall ensure that an up to date record of maintenance and examinations is kept. Each forklift and side loader must be marked with the following:- A unique identification number stamped on the body frame. Safe working load stamped/painted on the body frame.
Page 6 of 12 Each fork arm shall be marked permanently with its specified capacity and the specified load centre distance D in Fig.1. An example of such marking for a fork arm having a specified capacity of 750 Kg at 500mm. specified load centre distance would be :- 750 x 500. 6 Maintenance 6.1 All vehicles must be subject to maintenance and testing in accordance with manufacturers recommendations. This must be recorded and an indication of that maintenance having been carried out must be apparent or available to the user. 6.2 When a vehicle is hired and the hire company undertakes to perform maintenance, it is the hirer's (user's agent) responsibility to ensure that a satisfactory maintenance programme exists and that the vehicle is made available for it to be implemented. 6.3 All working parts must be thoroughly examined by a competent person at least once in every six month period and after an accident, major repair or modification. The examination and the vehicles fitness for continued safe use must be recorded.
Page 7 of 12 7 Modifications Modifications to vehicles, or any part thereof, that may affect safety must be approved by the manufacturer. Modifications to vehicles acquired for use on stations, that may affect the safety of railway operations must be approved by the infrastructure owner. 8 Statutory Requirements 8.1 In the event of an accident or dangerous occurrence, the requirements of the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 1985 (RIDDOR) and The Railways (Notice of Accidents) Order 1986, must be complied with. 8.2 Under the requirements of the Road Traffic Act 1991, all mechanically propelled vehicles being driven in public places, must carry a Driver's Logbook to record the name of the driver using the vehicle and the date and time of operation. It is recommended that modified vehicle Log Book BR2414 (Issue 92), or equivalent is used. 8.3 Where a vehicle is driven in a public place, operators must hold a current valid driving licence and the vehicle must be registered and licensed in accordance with the Vehicle (Excise) Act 1971. 9 Training and Authorisation 9.1 Persons selected for training and assessment to operate, shall have the following attributes:- be a minimum age of 18 years at the time of assessment: be medically fit according to the requirements of HSE document HS(G)6 and meet the specific railway for medical fitness as appropriate ( GO/ZT0005 - Medical Fitness of Persons Competent in Personal Track Safety or where employed within a workshop environment GM/PT0002 - Medical Fitness of Workshop Staff). be able to judge distances, heights, clearances and assess weights. physically capable of operating a forklift truck or side loader.
Page 8 of 12 9.2 Operators must receive training and be assessed in the operation of the specific type of vehicle and must carry the appropriate authorisation certificate while operating. The training shall be in accordance with the requirements of Approved Code of Practice (ACOP) Rider Operated Lift Trucks-Operator Training. 9.3 Maintenance craftsmen for forklift trucks or side loaders should receive appropriate training in order that they may carry out operational checks after completion of maintenance or repairs/adjustments to ensure that such a vehicle is left in a safe working order. 9.4 For battery operated forklift trucks or side loaders, operators/craftsmen shall be trained to charge/change batteries in accordance with manufacturers' instructions. 9.5 Trainee operators who have completed formal training and have satisfied the examiner of their competence in safe use and operation of the vehicle, may be formally authorised to operate the vehicle by their manager and issued with a full certificate of authorisation specific to the type(s) of vehicle concerned. 9.6 Authorisation certificates shall be allocated unique serial numbers which must be recorded by the issuing manager's department. The certificate will detail the following information:- Unique serial number. Business/Franchise Name. Station/Depot of validity. Name of Operator (in full). Type of Vehicle(s). Examiner's signature. Issuing Manager. Date of issue. Expiry date (2 years from date of issue). 9.7 An operator must receive additional training and pass a further examination before he may be authorised to operate vehicles belonging to different classification groups (e.g. driver operated, pedestrian operated or vehicles having different means of propulsion). 9.8 Operators must be re-assessed and reauthorised every two years.
Page 9 of 12 10 Safe System of Work 10.1 The organisation responsible for the operation of vehicles must produce a safe system of work which takes account of a risk assessment in the local operating environment and ensure it is implemented. Appropriate supervision must be provided. As a minimum the following points must be considered when producing the safe system of work: 10.2 The person in charge of the operation must assess the following:- the loads to be lifted and moved the working area the operating radii. 10.3 Should the forklift truck/side loader be required to work where it may foul a line on which trains are required to run, Section T of the Rule Book must be applied. 10.4 When a Safe Load Indicator (S.L.I.) on a forklift truck or side loader is found to be defective, the operator must report it to the manager. The machine may only continue in use if an alternative safe system of work is introduced but under no circumstances may it be used as a crane with a defective S.L.I. 10.5 Each vehicle should have an individual log book where tests, checks, repairs and adjustments shall be recorded. Neither the operator nor any other person should make any repair or adjustment unless they are trained and authorised to do so. 10.6 Operators must carry out pre operational checks in accordance with the manufacturers instructions before using the vehicle. If any item is found to be defective the fault must be reported to the supervisor. On receipt of such report the supervisor shall arrange for rectification of the fault and if necessary take the truck out of commission until such a repair has been carried out. 10.7 Before commencing any lifting duty the operator must, by reference to the duty table, assess the lifting duty within which the forklift/side loader will work and select the appropriate setting for the safe load indicator or other warning device where fitted. 10.8 When negotiating gradients the operator of a fork lift truck/side loader must:
Page 10 of 12 Carry loads with the forks pointing up the gradient. Point the forks downhill when unloaded. Adjust tilt to suit gradient. Take any other safety precautions to ensure safe movement. 10.9 Special care must be taken by the operator when turning across a gradient or on a cambered surface. 10.10 Forklift trucks are normally designed to negotiate gradients of 1 in 10. If this gradient is likely to be exceeded then the necessary derating must be agreed with the manufacturer. 10.11 The mechanical load/reach indicator shall at all times remain in working order. In the event of damage, or defect to the indicator, the supervisor shall withdraw the forklift truck/side loader from service immediately and inform the maintainer. 10.12 The operator of a forklift truck/side loader is responsible for ensuring that the forks are properly engaged with a stillage or pallet before lifting it. "properly engaged" means fully inserted and centrally placed. 10.13 The load must be lifted by a fork lift truck with the mast vertical or tilted slightly backwards. 10.14 Operators of side loaders must ensure the mast is fully retracted and the load is resting on the platform before selecting the travel motion. 10.15 No lifting operations shall be carried out where there is any doubt regarding the ability of the operating surface to withstand concentrated loads imposed by the wheels of the vehicle. 10.16 If there is any evidence of drains, culverts or other signs of building construction beneath the operating surface the Department responsible for the maintenance of the area must be consulted first. 10.17 No operation involving a lifting appliance shall be carried out where there is any doubt about clearances between a part of the appliance and any possible obstruction. Consideration must be given to the proximity of hazards such as nearby structures, telephone wires or similar services.
Page 11 of 12 10.18 When the site of work is beneath, or in the vicinity of overhead traction wires, or electricity supply cables, GC/OG0020 - The Control, Safe Use and Operation of Plant Working in the Vicinity of Overhead Electric Supply Lines must be followed. 10.19 When work is to take place in the vicinity of a conductor rail the provisions of the DC Electrified Line Working Instructions must be followed. 10.20 Where pallets are too large to be handled safely by the forks on the appliance, then consideration of the use of extension sleeves should be made. This may result in a reduction in the maximum capacity of the appliance. 10.21 When travelling the operator must ensure that the forks or the load are off the ground by not more than 300 mm (12 inches) and with the appropriate degree of back tilt of the mast consistent with safe operation. Loads must not be raised or lowered whilst travelling except when positioning the load. When appliances with hinged forks are travelling without a load, the forks must be raised to the vertical position. 10.22 Operators of fork lift trucks must take care that other persons are well clear of the machine, and particularly of the empty forks, which may not readily be seen. 10.23 Operators of fork lift trucks must not reach through the mast to adjust the load, or for any other purpose. 10.24 When appliances are left unattended they must be parked in an approved position clear of and parallel to adjacent lines where they will not be a hazard to any other operations. The hand brake shall be applied and the ignition key must be removed. 10.25 When parking a fork lift truck, the forks must be levelled, fully lowered, free of load and positioned safely clear of any other operations. 11 Personal Protective Equipment Personal protective equipment shall be provided for operators and supervisors and those who may be affected by the operation of the forklift truck or side loader.
Page 12 of 12 As a minimum the following items must be issued:- Safety footwear High visibility clothing Safety helmet (where applicable) Ear defenders (where applicable) 12 Related References H & SE - HS(G)6 - Safety in Working with Lift Trucks. European Council Directives 86/663 & 89/240. Approved Code of Practice - Rider Operated Lift Trucks - Operator Training.