Standard Operating Procedure



SOP 2.8: Powered Industrial Trucks (Forklifts)

Contents

1. Introduction 1

2. Regulatory and contractual requirements 1

3. Training………………………………………………………………………………………..1

4. Program administration 2

5. Maintenance Procedures 3

6. Recordkeeping…………….………………………………………………………………..4

Attachments:

A. Written test for forklift operators………………………………………………….5

B. Operator's Daily Checklist (gas, LPG, diesel) .7

C. Operator's Daily Checklist (electric) .8

1. Introduction

This Household Hazardous Waste (HHW) Program shall ensure safe operation of forklifts in compliance with OSHA requirements. Powered Industrial Trucks (referred to as “forklifts” in this SOP) are used for material handling. These may include fork, platform, and motorized hand trucks, as well as other specialized units powered by electric motors or internal combustion engines.

2. Regulatory and contractual requirements

HHW program and state agency contract (Exhibit A, parts A and B), Federal and Minnesota OSHA 29 CFR, 1910.178, 5205.0116 and 1910.178(l). Forklift operations shall meet ANSI B56.1 standards.

3. Training

3.1 The Facility Manager is the designated staff responsible for coordinating all equipment training. Only trained staff shall be authorized to operate forklifts and shall be trained in the following:

• Forklift-related topics (e.g., characteristics, operation, vehicle limitations)

• Workplace-related topics or hazards due to the characteristics of the workplace (e.g., surface conditions, proper loading, pedestrian traffic)

• Specific to each piece of equipment

3.2 Training shall consist of:

• Classroom training including a written test; see Attachment A of this SOP.

• Hands-on training

• Evaluation of the trainee’s practical skill

3.3 Initial training shall be conducted prior to operating forklifts. Operators’ practical skills shall be re-evaluated once every three years. Refresher training shall be provided whenever the:

• operator has been observed to operate in an unsafe manner

• operator has been involved in an accident or near-miss incident

• operator has received an evaluation regarding unsafe actions

• operator is assigned to a different type of forklift

• conditions in the workplace change in a manner that could affect safe forklift operation

3.4 Training shall be performed by persons who have the knowledge, qualifications, and experience to Instruct operators and evaluate their competence. Operator certifications may be revoked due to unsafe actions. Designated staff is responsible for:

• coordinating training

• maintaining the knowledge, skills, and expertise to present effective training

• assessing the skills and knowledge of forklift operators

• certifying only skilled and knowledgeable operators

• revoking operator certification if it becomes apparent that the operator seriously endangers him/herself, other staff and/or property

• certifying that each operator has been trained and has passed a written test and a practical evaluation

4. Program administration

4.1 Written policy. Designated staff shall be responsible for:

• maintaining records (e.g., training, operator certification, maintenance checklists)

• periodically reviewing policy and revise as necessary

• ensuring preventative maintenance and repair of forklifts; see SOP 5.1 Equipment Maintenance

• ensuring safety deficiencies of forklifts are remedied promptly

4.2 Forklift operator responsibilities

The Facility equipment operator shall be responsible for:

• inspecting forklifts; once per shift and reporting unsafe conditions

• following OSHA and HHW facility forklift operating rules

• consistently demonstrating safe driving habits

• immediate reporting of all accidents and near misses to designated staff

• removing unsafe forklifts from operation

• being aware of pedestrian hazards

• constantly being aware of other forklift traffic hazards

5. Maintenance procedures

5.1 Forklift inspection and maintenance

Each forklift shall be inspected by the first operator prior to starting a new shift. Completed inspection checklists shall be reviewed by designated staff and kept on file for at least six months. If deficiencies are noted that prevent safe operation, the forklift shall be taken out of service until the repairs have been completed. Check with the equipment manufacturer for additional recommendations and/or inspection checklists. To view an example inspection checklist (or use an equivalent form); see Attachments B & C of this SOP.

5.2 Changing and charging forklift batteries

Forklift battery maintenance and operation practices shall include:

• prohibiting smoking in battery charging areas

• preventing ignition sources in battery charging areas

• ensuring metallic objects (tools) are kept away from battery terminals and unguarded conductors

• following specific battery charger manufacturer recommended procedures

• ensuring an eyewash station is positioned nearby if there is a risk of acid splashing in the battery charging area

• carefully managing any spilled acid

• ensuring only trained and authorized staff remove batteries from forklifts

5.3 Control of emissions from internal combustion engines

Carbon monoxide levels shall be monitored where forklifts are propelled by internal combustion engines, while operated indoors. Minnesota OSHA’s 8-hour time-weighted average exposure limit for carbon monoxide is 35 parts per million (ppm) with a ceiling limit of 100 ppm. Monitoring shall:

• be conducted quarterly

• ensure tail-pipe exhaust gases do not contain more than one percent carbon monoxide (measured at idle and at three-fourths throttle during final engine tuning in a regular maintenance program)

• have results posted for staff information and kept on file

5.4 Preparation for loading or unloading

Before forklifts enter the back of a truck or trailer to load or unload, the brakes shall be set and wheels chocked. If trailers are not attached to tractors, fixed jacks may be necessary to support the trailer and prevent it from upending. See SOP 4.12 Waste Staging for Shipment.

5.5 Loading trucks

Only loads within the rated capacity of the forklift may be handled safely. Loads shall be:

• stable and safely arranged

• kept as close as possible to the forklift with the forks tilted back slightly

• monitored for safe clearance through aisles and doorways

• kept safe by using dock boards (bridge plates) constructed with sufficient strength, when loading or unloading operations are taking place between vehicles and docks

5.6 Forklift operations

Only trained, authorized persons are allowed to operate forklifts. Forklift operating guidelines include:

• no riders are allowed

• when left unattended, the forks shall be lowered, the power shall be shut off, and the parking brakes shall be engaged

• no driving in areas where potential flammable gases or vapors may be present, unless the forklift is especially designed for that purpose

• while parked: do not block exits, accesses to stairways, eyewash stations, electrical panels, or fire equipment

• operating at speeds that will permit a quick and safe stop

• driving slowly while turning

• maintaining a safe distance between forklift and other moving objects

• operating under control at all times

• driving slowly and sounding horn when passing through areas with an obstructed view

• looking in the direction of travel

• traversing ramps slowly and with caution

• preventing stunt driving and horseplay as such behavior shall be subject to disciplinary action

• avoiding objects in the roadway

• ensuring provisions are made to assure no one will be passing directly under hoisted or suspended loads

6. Recordkeeping

6.1 Designated staff shall maintain the following records:

• Certification of training which includes the name of operator, date of training, evaluation, and name of trainer.

• Pre-operation inspection checklists (6 months). See Attachment B or C of this SOP.

Attachment A: Written Test for Forklift Operators

|Name: ___________________________________________ Date: ________________ Score:_____ |

|Answer the following questions by filling in the blank, circling True or False, or circling the letter of the correct choice. |

|1. A lift truck training program helps to: |11. A truck traveling at 8.7 miles-per-hour is traveling approximately: |

|Reduce maintenance costs |9 feet per second |

|Increase efficiency |11 feet per second |

|Reduce accidents |13 feet per second |

|All of the above. |16 feet per second |

|2. The maximum allowable load should be indicated on the dataplate. |12. Staff is responsible for reading the Operator’s Manual for any type |

|True |truck operated: |

|False |True |

| |False |

|3. Equipment dataplates and decals must be in legible condition. |13. The load backrest extension is connected to the: |

|True |Mast |

|False |Lift cylinder |

| |Forks |

| |Carriage |

|4. The ____________ is a safety device designed to protect the driver from|14. Loads should be carried with the mast tilted forward. |

|falling objects. |True |

| |False |

|5. A raised load stabilizes the truck. |15. Data plates provide information on the trucks: |

|True |Height and width dimensions |

|False |Type of liquid fuel |

| |Maximum lift height |

| |Required safety equipment |

|6. What is the general weight ratio of truck to capacity load? |16. OSHA requires that employers offer operator training. |

|1:1 |True |

|2:1 |False |

|3:1 | |

|4:1 | |

|7. The rear-end steering of lift trucks: |17. It is not the responsibility of lift truck operators to protect |

|causes the rear end to swing more than an auto |pedestrians in the work area. |

|is about the same as an auto |True |

|swings less than an auto |False |

|allows the truck to take sharp turns at high speeds | |

|8. Lift trucks with four wheels are supported at four points: |18. The fulcrum point is a vertical line through the middle of: |

|True |Drive wheel hub |

|False |Center of gravity |

| |Operator compartment |

| |Counterweight |

|9. When traveling with a load, the forks should be off the floor: | |

|18 inches | |

|6 – 8 inches | |

|2 feet | |

|At stacking height | |

|10. Equipment modifications and additions which affect capacity should not|Answers: |7. A |14. F |

|be made without the manufacturer’s prior approval. |1. D |8. F |15. C |

|True |2. T |9. B |16. A |

|False |3. T |10. T |17. F |

| |4. Cage |11. C |18. A |

| |5. F |12. T | |

| |6. B |13. A | |

• Attachment B

Operator's Daily Checklist: Internal Combustion Engine Industrial Forklift—Gas/LPG/Diesel Forklift

Forklift number: ______________________

|Visual checks: |Operational checks |

|Fluid levels (coolant, oil, hydraulic, brake) |Horn |

|Fuel level |Service and/or parking brakes |

|Obvious damage and/or leaks |Seat belt and/or lap bar |

|Tire condition |Hydraulic controls |

|Head, tail and warning lights |Temperature gauge |

|Hour meter |Steering |

|Other gauges and instruments |Other: |

|Unit cleanliness | |

|Other: | |

|Date |Operator |

|Obvious damage or leaks |Horn |

|Tire condition |Steering |

|Battery plug connection |Service and/or parking brakes |

|Note: Be sure battery plug connection is tight. | |

|Head, tail, and warning lights |Seat belt and/or lap bar |

|Fluid levels (oil, hydraulic, brake) |Hydraulic controls |

|Hour meter |Other: |

|Other gauges and instruments | |

|Battery charge indicator level | |

|Other: | |

Date |Operator |Battery

connection |Battery charge |Brakes |Lights /horn |Hour meter |Steering

/tires |Hydraulics |Forks |Overhead

guards |Other | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |For additional comments on circled items, see back of this sheet.

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