Forklift- Safe Operation & Maintenance

1.0 General

(a) Fork lift trucks shall bear a label or some other identifying mark indicating serial number. Also, forklifts are to be registered by RTO authorities. Thus there shall be two numbers on the forklifts – RTO number and the equipment tag number given by the company.
(b) Modifications and additions that affect capacity and safe operation shall not be performed without the manufacturer’s prior written approval, where such permission for a modification is granted capacity, operation, and maintenance instruction plates, tags, or decals shall be changed accordingly
(c) If the fork lift truck is equipped with front-end attachments other than factory installed, they must be marked to identify the attachments, and show the approximate weight of the fork lift truck and attachment combination at maximum elevation with load laterally centered. All nameplates and markings must be maintained in a legible condition.

2.0 Fork Lift Truck Operations

In areas where fork lift truck are to operate the atmosphere shall be monitored and classified by the competent person as hazardous or non hazardous prior to the consideration of industrial fork lift trucks being used.
Area supervisors and fork lift truck operators shall ensure:
Equipment designed only for stand-up operation shall not be used.
(a) Equipment which does not have roll-over protective structure (ROPS) or adequate canopy protection shall not be used.
(b) Only trained and authorized operators shall be permitted to operate a fork lift truck.
(c) Fork lift trucks shall not be driven up to anyone standing in front of a fixed object.
(d) Persons shall not be allowed to stand or pass under the elevated portion of a fork lift truck, whether loaded or empty.
(e) Unauthorized personnel shall not be permitted to ride on powered industrial fork lift trucks unless a safe place to ride has been provided.
(f) Arms or legs must not be placed between the uprights of the mast or outside the running lines of the fork lift truck.
(g) A safe distance shall be maintained from the edge of ramps or platforms while on any elevated deck, or platform or freight car.
(h) Fork lift trucks shall not be used for opening or closing freight doors.
(i) There shall be sufficient headroom under overhead installations, lights; pipes, sprinkler system etc.
(j) An overhead guard shall be used as protection against falling objects.
(k) A load backrest extension must be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.
(l) Where a fork lift truck is found to be in need of repair or in any way unsafe, it shall be taken out of service until restored to safe operating condition.
(m) Fuel tanks shall only be filled with the engine switched off.
(n) Spillage shall be avoided. If oil or fuel is spilled it shall be carefully washed away or allowed to completely evaporated and the fuel tank cap replaced before restarting engine.
(o) No fork lift truck is to be operated with a leak in the fuel system.
(p) Open flames shall not be used for checking electrolyte level in storage batteries or gasoline level in fuel tanks.
(q) Fork lift truck shall not be used for the lifting of personnel.
(r) Seat belts shall be provided on all fork lift trucks

3.0 Traveling

The following conditions apply to all fork lift trucks:
(a) Fire aisles, access to stairways, and fire equipment shall be kept clear at all times.
(b) All traffic regulations shall be observed, including authorised plant speed limits.
(c) A safe distance shall be maintained approximately three fork lift truck lengths from the fork lift truck ahead.
(d) The right of way shall be yielded to ambulances, fire trucks, or other vehicles in emergency situations.
(e) Do not pass other fork lift trucks travelling in the same direction at intersections, blind spots, or other dangerous locations.
(f) 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 must travel with the load trailing.
(g) Care shall be taken when crossing railroad tracks.
(h) Parking closer than 3 meters from the centre of railroad tracks is prohibited.
(i) When ascending or descending a grade drive slowly and look in the direction of and keep a clear view of the path of travel.
(j) When ascending or descending grades in excess of 10%, loaded fork lift trucks must be driven with the load up grade and, where possible, the load shall be tilted back and raised only as far as necessary to clear the road surface.
(k) Under all travel conditions the fork lift truck shall be operated at a speed that will permit it to be brought to a stop in a safe manner.
(l) No form of horseplay whilst in charge of a fork lift truck shall be permitted.
(m) Fork lift trucks must travel slowly on wet and slippery floors.
(n) Duck boards or bridge plates shall be properly secured before they are driven over.
(o) Duck board or bridge plates shall be driven over carefully and slowly and their rated capacity never exceeded.
(p) Elevators must be approached slowly and entered squarely after the elevator car is properly leveled. Once on the elevator, the controls are neutralized, power shut off, and the brakes set.
(q) Motorized hand fork lift trucks must enter elevators or confined areas with load end forward.
(r) While negotiating turns, reduce the speed to a safe level and turn the hand
steering wheel in a smooth, sweeping motion.

4.0 Loading

(a) Only stable or safely arranged loads are to be handled. Caution must be
exercised when handling off-centre loads that cannot be centered. The load must be within the rated capacity of the fork lift truck.
(b) Long or high, including multiple-tiered, loads that may affect capacity shall be adjusted.
(c) Fork lift trucks equipped with attachments shall be operated as partially loaded fork lift trucks when not handling a load.
(d) Blades shall be placed under the load as far as possible and the mast should be carefully tilted backward to stabilize the load.
(e) Use extreme care when tilting the load forward or backward, particularly with high stacking.
(f) Tilting forward with blades elevated is 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.
(g) When stacking, only enough backward tilt to stabilize the load is to be used.

5.0 Fork Lift Trucks and Highway Trucks and Trailers

The following conditions shall apply:
(a) The brakes of highway trucks must be set, wheel chocks placed under the rear wheels to prevent rolling while using fork lift trucks inside for loading or unloading.
(b) Wheel stops or other recognized positive protection shall be provided to prevent trucks or trailers from moving during loading or unloading operations and while dock boards or bridge plates are in position.
(c) Fixed jacks may be necessary to support a semi trailer and prevent upending during loading or unloading when the trailer is not coupled to a tractor.
(d) The flooring of highway trucks and trailers shall be checked for breaks and
weakness before they are driven onto

6.0 Inspection and Maintenance of Fork Lift Trucks

(a) Fork Lifts shall be subject to the requirements of the Plant, Vehicle and Heavy Equipment Inspection and Maintenance Procedure, and also require a color coded inspection tag as per the Inspection and Color Coding of Plant, Equipment and Tools Procedure.
(b) Fork Lifts shall have the SWL clearly indicated.
(c) Fork Lifts shall be numbered for safety inspections and record keeping purposes.
(d) The operator shall visually inspect the Fork Lift on a daily basis prior to placing it in service.
(e) Industrial fork lift 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 fork lift trucks are used on a round-the-clock basis, they shall be examined after each shift. Defects, when found, shall be immediately reported and corrected.

7.0 Causes for a fork lift truck to be taken out of service for overhaul or maintenance

Any fork lift truck not in safe operating condition will be removed from service and repaired by authorized personnel as per the following:
(a) No repairs shall be made in on forklift trucks inside the RLC operating plant. Major repairs shall not be made on the jobsite.
(b) Repairs to the fuel and ignition systems of fork lift trucks which involve fire hazards shall be conducted only in locations designated for such repairs.
(c) Fork lift trucks in need of repairs to the electrical system shall have the battery disconnected prior to such repairs.
(d) All parts of any fork lift truck requiring replacement shall be replaced only by parts equivalent as to safety with those used in the original design.
(e) Fork lift 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.
(f) Fork lift trucks shall not be altered either by the addition of extra parts not provided by the manufacturer or by the elimination of any parts.
(g) Additional counter weighting of fork lift trucks shall not be done unless written approval is provided by the fork lift truck manufacturer.
(h) The following daily checks shall be carried out:
(i) Water mufflers shall be filled daily or as frequently as is necessary to prevent depletion of the supply of water below 75% of the filled capacity.
(j) Vehicles with mufflers having screens or other parts that may become clogged shall not be operated until they have been cleaned.
(k) Any hazardous sparks or flames from the exhaust system shall immediately be removed from service and not returned to service until the cause for the emission of such sparks and flames has been eliminated.
(l) When the temperature of any part of any fork lift 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.
(m)Fork lift trucks shall be kept in a clean condition, free of lint, excess oil, and grease.
(n) Only non-combustible agents should be used for cleaning fork lift trucks.
(o) Only high flash point solvents at or above 380C may be used. Precautions
regarding toxicity, ventilation, and fire hazard shall be consistent with the agent or solvent used. (review MSDS).

7.0 Charging and Changing of Storage Batteries

(a) For all charging and related activities the following conditions shall apply:
(b) Fork lift trucks shall be properly positioned and brake applied before attempting to change or charge batteries.
(c) Smoking, open flames, sparks, or electric arcs in battery charging areas shall be prohibited.
(d) A safety shower and/or eye wash facility or other acceptable means of quick drenching of the body shall be within a safe distance of the charging facility.
(e) Battery charging installations shall be located in areas designated for that
purpose.
(f) Facilities shall be provided for flushing and neutralizing spilled electrolyte, fire protection, protecting charging apparatus from damage by fork lift trucks, and adequate ventilation for the dispersal of fumes from gassing batteries.
(g) Reinstalled batteries shall be properly positioned and secured in the fork lift truck. A siphon shall be provided for handling electrolyte.
(h) When charging batteries, acid shall be poured into water; water shall not be poured into acid.
(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) Tools and other metallic objects shall be kept away from the top of uncovered batteries.

8.0 Checklist for Forklift

ITEMS TO BE INSPECTED
	OPERATOR’S CAB	OK / Not OK
1	Step, Door Handle, Latch
2	Seat, Seatbelt, Cleanliness
3	Windshield, Cab Glass
4	Windshield Wiper, Washer
5	Fan (Air Circulation)
6	Sun Visor
7	Speedometer
8	Tachometer
9	Audio, Visual Alarms
10	Indicators, Gauges
11	Switches
12	Mirrors, Rear, Left, Right, Winch
	ELECTRICAL SYSTEM
13	Headlights, Low / High Beam
14	Signal/Hazard Lights, Front Rear
15	Tail Lights, Brake Lights
16	Horn
17	Back Up Lights / Alarm
18	Flashing Light, Cab Mounted
19	Electrical System Wiring
20	Batteries, Covers, Hold Downs
21	Battery Terminals, Cables
	ENGINE
22	Oil Leaks
23	Coolant Leaks
24	Fuel Leaks
25	Fan, Guards, Belts
26	Abnormal Exhaust Smoke
27	Exhaust System, Leaks, Silencer
28	Radiator, Leaks, Cap, Gasket
	FUEL TANK
29	Leaks, Cap, Gasket
30	Mounting Brackets, Straps
31	Fuel Lines, Connections, Leaks
	OPERATOR STATION
32	Throttle Control Pedal
33	Brake Pedal
34	Transmission Controls
35	Engine Manual Shutoff
36	Foot Pedal Inching Control
37	Hydraulic Controls
	DRIVE TRAIN
38	Torque Converter, Oil Leaks, Slippage
39	Inching Control
40	Clutch, Free Play, Slippage, Noise
41	Transmission, Oil Leak, Noise
42	Operates in all Gears, Ranges
43	Transmission Pump, Oil Leaks, Noise
44	Drive Axle Housing, Hubs, Oil Leaks
45	Differential, Oil Leak, Noise
46	Drive Shaft, Universal Joints
	STEERING SYSTEM
47	Hydraulic Pump, Noise, Oil Leaks
48	Orbital Pump, Oil Leaks
49	Control valve, Oil Leaks
50	Steering Cylinders, Oil Leaks
51	Hoses, Tubes, Connections, Oil Leaks
	BRAKE SYSTEM
52	Front Brake Drums, Linings
53	Brake Cylinders, Brake Lines, Adjusters
54	Parking Brake
	FRONT AXLE
55	Centre Pin, Bearing
56	Spindles, King pins
57	Linkage
	HYDRAULIC SYSTEM
58	Hydraulic Pump, Oil Leaks, Noise
59	Control Valves, Oil Leaks
60	Hydraulic tank, oil leaks, cap, seals
61	Tank mountings, straps
62	Hoses, Tubes, Connections, Oil Leaks
63	Lift Cylinders, Oil Leaks
64	Tilt Cylinders, Oil Leaks
65	Side Shift Cylinders, Oil Leaks
	MAST ASSEMBLY
66	Mountings
67	Inner Section, Rollers
68	Lift Chains, Backrest, Fork Carriage
69	Forks, Cracks, Bent Sections, Hinge Pins
	SAFETY
70	Load Chart
71	Fire Extinguisher, Capacity, Date Charged
	ENVIRONMENTAL
72	Emergency Spill Kit
	TYRES
73	Front Tires
74	Rear Tires
75	Wheels, Rims, Lock Rings
76	Mounting Studs, Clamps Nuts