Page 1 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 1. Purpse Frklift & Mtrized Pallet Jack Safety Prgram Material handling is a significant safety cncern. During the mvement f prducts and materials, there are numerus pprtunities fr persnal injury and prperty damage if prper prcedures and cautin are nt used. This plicy applies t all pwered industrial tucks, hists & lifting gear. The infrmatin in this plicy shall be used t train prspective industrial truck peratrs and prvide the basis fr refresher and annual retraining. OSHA reference fr Pwered Industrial Trucks is 1910.178. 2. Respnsibilities Management: Prvide adequate training in safe peratin f all equipment used t mve r access materials Prvide equipment that is safe t perate Implement an "Out f Service" prgram fr damaged equipment Nt allw mdificatin t equipment except thse authrized in writing by the equipment manufacturer Establish safe perating rules and prcedures Supervisrs Mnitr safe peratins f material handling equipment Ensure all equipment is safety checked daily Tag "Out f Service" any damaged equipment Emplyees 3. Hazards Operate nly that equipment fr which they have been specifically trained and authrized Cnduct required daily pre-use inspectins Reprt any equipment damage r missing safety gear Fllw all safety rules and perating prcedures Falling lads Overlading f equipment Impact with equipment Piercing f cntainers Lading dck rll ff
Page 2 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Chemical cntact - battery acid Fires during refueling 4. Hazard Cntrls Cntrl f equipment keys Authrized fueling & recharge areas Prper palletizing f material Marked travel lanes Equipment warning lights Seat belts Munted fire extinguishers 5. Pre-Qualificatin Revisin: 2 Nv 2002 All candidates fr Pwered Industrial Truck (PIT) peratrs must meet the fllwing basic requirements prir t starting initial r annual refresher training: 6. Training Must have n adverse visin prblems that cannt be crrected by glasses r cntacts N adverse hearing lss that cannt be crrected with hearing aids N physical impairments that wuld impair safe peratin f the PIT N neurlgical disrders that affect balance r cnsciusness Nt taking any medicatin that affects perceptin, visin, r physical abilities Training fr Pwered Industrial Truck (PIT) Operatrs shall be cnducted by a qualified instructr r Ardent-designated cmpetent persn. All peratinal training shall be cnducted under clse supervisin. All training and evaluatin must be cmpleted befre an peratr is permitted t use a Pwered Industrial Truck (frklift, etc.) withut cntinual & clse supervisin. Trainees may perate a pwered industrial truck nly: Under the direct supervisin f persns, selected by management, wh have the knwledge, training, and experience t train peratrs and evaluate their cmpetence; and Where such peratin des nt endanger the trainee r ther emplyees. Training Cntent Training cnsists f a cmbinatin f frmal instructin, practical training (demnstratins perfrmed by the trainer and practical exercises perfrmed by the trainee), and evaluatin f the peratr's perfrmance in the wrkplace.
Page 3 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 Initial Training: Pwered industrial truck peratrs shall receive initial training in the fllwing tpics: Truck-related training tpics: Operating instructins, warnings, and precautins fr the types f truck the peratr will be authrized t perate Differences between the truck and the autmbile Balance and cunter-balance Truck cntrls and instrumentatin: where they are lcated, what they d, and hw they wrk Engine r mtr peratin Steering and maneuvering Visibility (including restrictins due t lading) Frk and attachment adaptatin, peratin, and use limitatins Vehicle lad capacity Vehicle stability Ramps Any vehicle inspectin and maintenance that the peratr will be required t perfrm Refueling and/r charging and recharging f batteries Operating limitatins and distances Any ther perating instructins, warnings, r precautins listed in the peratr's manual fr the types f vehicle that the emplyee is being trained t perate. Wrkplace-related tpics: Surface cnditins where the vehicle will be perated Cmpsitin f lads t be carried and lad stability Lad manipulatin, stacking, and unstacking Pedestrian traffic in areas where the vehicle will be perated Narrw aisles and ther restricted places where the vehicle will be perated Hazardus (classified) lcatins where the vehicle will be perated Ramps and ther slped surfaces that culd affect the vehicle's stability Clsed envirnments and ther areas where insufficient ventilatin r pr vehicle maintenance culd cause a buildup f carbn mnxide r diesel exhaust Other unique r ptentially hazardus envirnmental cnditins in the
Page 4 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram wrkplace that culd affect safe peratin Revisin: 2 Nv 2002 Refresher training and evaluatin. Refresher training, including an evaluatin f the effectiveness f that training, shall be cnducted t ensure that the peratr has the knwledge and skills needed t perate the pwered industrial truck safely. Refresher training in relevant tpics shall be prvided t the peratr when: The peratr has been bserved t perate the vehicle in an unsafe manner The peratr has been invlved in an incident r near-miss incident The peratr has received an evaluatin that reveals that the peratr is nt perating the truck safely The peratr is assigned t drive a different type f truck A cnditin in the wrkplace changes in a manner that culd affect safe peratin f the truck Once every 3 years an evaluatin will be cnducted f each pwered industrial truck peratr's perfrmance. Safe Operating Prcedures (SOP) & Rules Only authrized and trained persnnel will perate PITs. All PITs will be equipped with a headache rack, fire extinguisher, rtating beacn, back-up alarm and seat belts. Seat belts will be wrn by the peratr and must be fastened prir t starting the equipment The peratr will perfrm daily pre-use inspectins. See Appendix A, Daily Frklift Inspectin Frm (Yard Frklift), dcument O-SS-FRM-0095. Any safety defects (such as hydraulic fluid leaks; defective brakes, steering, lights, r hrn and/r missing fire extinguisher, lights, seat belt, r back-up alarm) will be reprted fr immediate repair r have the PIT taken "Out f Service". Operatrs will fllw the prper recharging r refueling safety prcedures. Lads will be tilted back and carried n mre than 6 inches frm the grund. Lads that restrict the peratr's visin will be transprted backwards. PITs will travel n faster than 5 mph r faster than a nrmal walk. Hard hats will be wrn by PIT Operatrs in high lift areas Eye prtectin must be wrn if the equipment des nt an enclsed cab Operatr will sund hrn and use extreme cautin when meeting pedestrians, making turns, and crnering. Passengers may nt ride n any prtin f a PIT. Only the peratr will ride PITs. "NO PASSENGERS" decals will be affixed n all PITs. The equipment must nly be used fr what it is intended and designed fr.
Page 5 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 If PITs are used as a man lift, an apprpriate man lift platfrm (cage with standard rails and te-bards) will be used. Aisle will be maintained free frm bstructins, marked and wide enugh (six feet minimum) fr vehicle peratin. Lift capacity will be marked n all PITs. Operatr will assure lad des nt exceed rated weight limits and the lad must be secured fr safe transprt. When un-attended, PITs will be turned ff, frks lwered t the grund and parking brake applied. All PITs (with exceptin f pallet jacks) will be equipped with a multi-purpse dry chemical fire extinguisher. (Minimum rating; 2A:10B:C) Operatrs are instructed t reprt all incidents, regardless f fault and severity, t Management. When lading rail cars and trailers, dck plates will be used. Operatrs will assure dck plates are in gd cnditin and will stre n edge when nt in use. Rail cars and trailers will be parked squarely t the lading area and have wheels chcked in place. Operatrs will fllw established Dcking/Un- Dcking Prcedures. Changing and Charging Strage Batteries Battery charging installatins shall be in areas designated fr that purpse. Facilities shall be prvided fr flushing and neutralizing spilled electrlyte, fr fire prtectin, fr prtecting charging apparatus frm damage by trucks, and fr adequate ventilatin fr dispersal f fumes frm gassing batteries. A cnveyr, verhead hist, r equivalent material handling equipment shall be prvided fr handling batteries. Reinstalled batteries shall be prperly psitined and secured in the truck. A carby tilter r siphn shall be prvided fr handling electrlyte. When charging batteries, acid shall be pured int water; water shall nt be pured int acid. Trucks shall be prperly psitined, and brake applied befre attempting t change r charge batteries. Care shall be taken t assure that vent caps are functining. The battery (r cmpartment) cver(s) shall be pen t dissipate heat. Smking is prhibited in the charging area. Precautins shall be taken t prevent pen flames, sparks, r electric arcs in battery charging areas. Tls and ther metallic bjects shall be kept away frm the tp f uncvered batteries.
Page 6 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 Trucks and Railrad cars Operatins The flring f trucks, trailers, and railrad cars shall be checked fr breaks and weakness befre they are driven nt. The brakes f highway trucks shall be set, and wheel chcks placed under the rear wheels t prevent the trucks frm rlling while they are barded with pwered industrial trucks. Wheel stps, r ther recgnized psitive prtectin shall be prvided t prevent railrad cars frm mving during lading r unlading peratins. Fixed jacks may be necessary t supprt a semi trailer and prevent upending during the lading r unlading when the trailer is nt cupled t a tractr. Psitive prtectin shall be prvided t prevent railrad cars frm being mved while dck bards r bridge plates are in psitin. If at any time a pwered industrial truck is fund t need repair, defective, r in any way unsafe, the truck shall be taken ut f service until it has been restred t safe perating cnditin. Trucks shall nt be driven up t anyne standing in frnt f a bench r ther fixed bject. N persn shall be allwed t stand r pass under the elevated prtin f any truck, whether laded r empty. Unauthrized persnnel shall nt be permitted t ride n pwered industrial trucks. Arms r Legs shall nt be placed between the uprights f the mast r utside the running lines f the truck. When a pwered industrial truck is left unattended, lad engaging means shall be fully lwered, cntrls shall be neutralized, pwer shall be shut ff, and brakes set. Wheels shall be blcked if the truck is parked n an incline. A safe distance shall be maintained frm the edge f ramps r platfrms while n any elevated dck, r platfrm r freight car. Trucks shall nt be used fr pening r clsing freight drs. There shall be sufficient headrm under verhead installatins, lights, pipes, sprinkler system, etc. An verhead guard shall be used as prtectin against falling bjects. It shuld be nted that an verhead guard is intended t ffer prtectin frm the impact f small packages, bxes, bagged material, etc., representative f the jb applicatin, but nt t withstand the impact f a falling capacity lad. A lad backrest extensin shall be used whenever necessary t minimize the pssibility f the lad r part f it frm falling rearward.
Page 7 f 10 Dcument N.: Sect: Traveling Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 Trucks shall nt be parked t blck fire aisles, access t stairways, r fire equipment. All traffic regulatins shall be bserved, including authrized speed limits. A safe distance shall be maintained apprximately three truck lengths frm the truck ahead, and the truck shall be kept under cntrl. The right f way shall be yielded t ambulances, fire trucks, r ther vehicles in emergency situatins. Other trucks traveling in the same directin at intersectins, blind spts, r ther dangerus lcatins shall nt be passed. The driver shall be required t slw dwn and sund the hrn at crss aisles and ther lcatins where visin is bstructed. If the lad being carried bstructs frward view, the driver shall be required t travel with the lad trailing. Railrad tracks shall be crssed diagnally wherever pssible. Parking clser than 8 feet frm the center f railrad tracks is prhibited. The driver shall be required t lk in the directin f and keep a clear view f the path f travel. Grades shall be ascended r descended slwly. When ascending r descending grades mre than 10 percent, laded trucks shall be driven with the lad upgrade. On all grades, the lad and lad engaging means shall be tilted back if applicable and raised nly as far as necessary t clear the rad surface. Under all travel cnditins, the truck shall be perated at a speed that will permit it t be brught t a stp in a safe manner. Stunt driving, and hrseplay shall nt be permitted. The driver shall be required t slw dwn fr wet and slippery flrs. Dck bards r bridge plates, shall be prperly secured befre they are driven ver. Dck bards r bridge plates shall be driven ver carefully and slwly, and their rated capacity never exceeded. Running ver lse bjects n the radway surface shall be avided. While negtiating turns, speed shall be reduced t a safe level by means f turning the hand steering wheel in a smth, sweeping mtin. Except when maneuvering at a very lw speed, the hand steering wheel shall be turned at a mderate, even rate.
Page 8 f 10 Dcument N.: Sect: Lading Fueling Safety Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 Only stable r safely arranged lads shall be handled. Cautin shall be exercised when handling ff-center lads which cannt be centered. Only lads within the rated capacity f the truck shall be handled. The lng r high (including multiple-tiered) lads which may affect capacity shall be adjusted. Trucks equipped with attachments shall be perated as partially laded trucks when nt handling a lad. A lad engaging means shall be placed under the lad as far as pssible; the mast shall be carefully tilted backward t stabilize the lad. Extreme care shall be used when tilting the lad frward r backward, particularly when high tiering. Tilting frward with lad engaging means elevated shall be prhibited except t pick up a lad. An elevated lad shall nt be tilted frward except when the lad is in a depsit psitin ver a rack r stack. When stacking r tiering, nly enugh backward tilt t stabilize the lad shall be used. Fuel tanks shall nt be filled while the engine is running. Spillage shall be avided. Spillage f il r fuel shall be carefully washed away r cmpletely evaprated and the fuel tank cap replaced befre restarting engine. N truck shall be perated with a leak in the fuel system until the leak has been crrected. Open flames shall nt be used fr checking electrlyte level in strage batteries r gasline level in fuel tanks. Smking is prhibited during fueling peratins Fuel nzzle must have psitive cntact with the tank prir t fueling. Maintenance f Pwered Industrial Trucks Any pwer-perated industrial truck nt in safe perating cnditin shall be remved frm service. Authrized persnnel shall make all repairs. Thse repairs t the fuel and ignitin systems f industrial trucks which invlve fire hazards shall be cnducted nly in lcatins designated fr such repairs. Trucks in need f repairs t the electrical system shall have the battery discnnected prir t such repairs. All parts f any such industrial truck requiring replacement shall be replaced nly by parts equivalent as t safety with thse used in the riginal design.
Page 9 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 Industrial trucks shall nt be altered s that the relative psitins f the varius parts are different frm what they were when riginally received frm the manufacturer, nr shall they be altered either by the additin f extra parts nt prvided by the manufacturer r by the eliminatin f any parts. Additinal cunter-weighting f frk trucks shall nt be dne unless apprved by the truck manufacturer. Industrial trucks shall be examined befre being placed in service and shall nt be placed in service if the examinatin shws any cnditin adversely affecting the safety f the vehicle. Such examinatin shall be made at least daily. Where industrial trucks are used n a rund-the-clck basis, they shall be examined prir t use each shift. Defects when fund shall be immediately reprted and crrected. When the temperature f any part f any truck is fund t be mre than its nrmal perating temperature, thus creating a hazardus cnditin, the vehicle shall be remved frm service and nt returned t service until the cause fr such verheating has been eliminated. Industrial trucks shall be kept in a clean cnditin, free f lint, excess il, and grease. Nncmbustible agents shuld be used fr cleaning trucks. Lw flash pint (belw 100 deg. F.) slvents shall nt be used. High flash pint (at r abve 100 deg. F.) slvents may be used. Safe Operatin Prcedure fr Charging LPG Tank N Smking. Mve LPG PIT utside fr refueling. Turn ff PIT. LPG tanks will be remved in the fllwing rder: shut ff service valve discnnect tank frm hse unbuckle and remve tank frm bracket LPG tanks will be replaced in t fllwing rder: place tank in bracket and re-buckle recnnect hse t tank and tighten firmly pen valve slwly and assure prper seal NOTE: Federal Law Prhibits dispensing an imprper fuel type int any Vehicle r int a nn-apprved fuel cntainer. In Case f LPG Leaks r Tank Rupture DO NOT start r mve the PIT. If fuel hse is leaking, Clse valve immediately and place PIT "Out f Service" until repaired.
Page 10 f 10 Dcument N.: Sect: Frklift and Mtrized Pallet Jack Safety Prgram Revisin: 2 Nv 2002 If tank ruptures, warn thers, immediately leave the area (at least 50 feet) and ntify Management. D nt re-enter the area until cleared by Management. Attachments Appendix A, Daily Frklift Inspectin Frm (Yard Frklift), dcument O-SS-FRM-0095.