Labor protection instruction for a stacker crane operator

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OCCUPATIONAL SAFETY AND HEALTH
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Labor protection instruction for a stacker crane operator

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General safety requirements

1.1. To operate a stacker crane, persons are allowed at least 18 years of age who have passed a medical examination, special training, passed exams and received a certificate for the right to operate a stacker crane.

1.2. Stacker crane operators must have a medical opinion on the possibility of performing work. Persons who do not have it are not allowed to work.

1.3. Before being allowed to work, the operator must undergo an introductory briefing on labor protection, primary briefing at the workplace and practically master the safe methods of operating a stacker crane, lifting, transporting and stacking goods. The passage of the briefing is documented by an entry in the briefing log. Repeated training at the workplace is carried out at least every 6 months.

1.4. The stacker crane operator must:

know the device and purpose of all mechanisms of a stacker crane, its individual elements, all equipment, have a second qualification group for electrical safety in accordance with the Safety Rules for the operation of consumer electrical installations;
have the skills required to operate and maintain all crane mechanisms;
know the range and purpose of lubricants used to lubricate the stacker crane;
be able to determine the suitability for work of ropes, lifting devices and containers;
know the rules for the safe movement of goods;
know the techniques for relieving people under voltage from the action of electric current, and ways to help them.

1.5. In case of contraindications to the performance of the previous work for health reasons, in accordance with the medical report, inform the administration of the enterprise about this.

1.6. The stacker crane operator is obliged to perform only the work that is entrusted by the administration and is part of his duties.

1.7. When performing loading and unloading operations, it is necessary to adhere to the accepted technology of cargo processing. It is not allowed to use methods that speed up the execution of technological operations, but lead to a violation of safety regulations.

1.8. In case of any questions related to its safe performance in the process of work, it is necessary to contact the person responsible for the safe performance of work.

1.9. If you notice a violation of the labor protection instructions by other workers or a danger to others, warn the worker who violates safety requirements, or inform the work manager about this.

1.10. In the process of work, the operator may be exposed to the following hazardous and harmful production factors: moving machines and mechanisms, transported and stored goods, increased dust content in the air of the working area, microclimate, dangerous voltage levels in the electrical circuit.

1.11. The operator must be provided with personal protective equipment:

cotton overalls;
dielectric galoshes;
dielectric gloves.
For outdoor work in winter additionally:
jacket with insulating lining;
trousers with insulating lining;
felt boots.

1.12. It is allowed to move loads only on a serviceable stacker crane. The operator of the stacker crane and the person responsible for maintaining the hoisting machines in good condition are responsible for working on faulty equipment.

1.13. Each stacker crane must have a watch log for shift registration and records of the work of the stacker crane.

1.14. During the work shift, the established regime of work and rest must be observed. Rest and smoke should only be in designated areas.

2. Safety requirements before starting work

2.1. Every day before starting work:

check the condition of the main components and parts (bolts, nuts, cotter pins, etc.) and, if necessary, tighten;
clean the assemblies and parts from dust, dirt and excessive lubrication;
make sure that the emergency brakes of all mechanisms are reliable;
check the condition of the hoisting rope and the correctness of its winding on the drum;
check side connections: fastening of telescopic grippers, gripper movement drives, control panels and handles, etc.;
check the serviceability and reliability of the guards of the moving and rotating mechanisms of the equipment;
check the place of work of the stacker crane, make sure there are no obstacles in the way.

2.2. Once a week, before starting work, it is necessary to carry out a technical inspection of the stacker crane in order to check the lubrication in gearboxes, assembly units and electrical equipment.

2.3. Immediately before starting work, the stacker crane operator must:

check the serviceability of the grounding;
test at idle and make sure that all mechanisms and electrical equipment work properly;
check the correct operation of instruments and devices that protect equipment from damage and ensure the safe operation of the operator and maintenance personnel of the warehouse;
check the correct laying of cables connecting the control panel of the stacker crane and the electric motor.

2.4. Faults found should not be repaired by yourself. The operator must make an appropriate entry in the log, report this to the head of the site (warehouse), call a locksmith or electrician. The stacker crane operator has the right to start work after the elimination of all malfunctions if there is a note in the journal about this by the person who eliminated the malfunction.

3. Safety requirements during work

3.1. It is not allowed to leave the stacker crane unattended, except for the established breaks; if it is necessary to leave the workplace, the operator must install the stacker crane in the parking area, put all control levers in the zero position, turn off the power of the stacker crane, close the door of the control cabin with a lock.

3.2. Before loading (unloading) and transporting a certain type of cargo by a stacker crane, it is necessary to set the fork width in accordance with the dimensions of this cargo. With respect to the vertical frame, the forks should be located symmetrically, their lower ends should be in the same plane.

3.3. It is not allowed to lift, transport cargo, the center of gravity of which is located at a greater distance from the front walls of the forks than recommended by the factory instructions, or cargo that exceeds in mass the rated load capacity of the stacker crane indicated on the control cab plate.

3.4. When lifting a load, it is not allowed:

to seize the load in the absence of a clearance under it, necessary for the free passage of the capture;
stack the load by grabbing a stacker crane with a loader and a crane.

3.5. The stacking of goods on the forks of a stacker crane should be carried out (in order to avoid injury by an overturned load) without the help of loaders. It is not allowed to be near the load or the stacker crane at this time.

3.6. Before leaving the cab of the stacker crane, the operator must first lower the load.

3.7. With simultaneous operation of stacker cranes and electric forklifts, the work areas of both should be separated by fences, excluding the possibility of their mutual collision.

3.8. The presence of unauthorized persons in the work area of the stacker crane is not allowed. Otherwise, the operator must stop the crane.

3.9. When transporting cargo with a stacker crane, the operator must comply with the following requirements:

turn on operating speeds only when the stacker crane moves along the aisles of the racks;
start and stop the mechanisms of the stacker crane smoothly, preventing the load from swinging;
transfer mechanisms from forward to reverse only after they have completely stopped;
lift only the load, the mass of which is known and does not exceed the capacity of the stacker crane;
lift cargo in a container filled no higher than its sides;
install pallets so that the goods do not hang from the cells of the racks.

3.10. Lifting and moving people with a stacker crane is not allowed.

3.11. Cargo handling of paints and varnishes, calcium carbide, acids, alkalis and other dangerous goods is allowed only with the help of stacker cranes made in explosion-proof design.

3.12 Stops of butt locks installed on the transfer trolley and the rail track of the rack stacker crane should be automatically removed after the docking of the transfer trolley and the rail tracks of the stacker cranes and automatically return to their original position after the locks are undocked. The failure of the locks docking stops should be immediately reported to the head of the section (warehouse).

3.13. The transfer of a rack stacker crane to and from a transfer cart is allowed only if the cart and the rail track of the rack stacker crane are connected to each other by a butt lock.

4. Safety requirements for repairs and maintenance

4.1. Maintenance of stacker cranes is carried out at the points of their exit from the inter-rack aisles. For maintenance of drives and mechanisms located below, a platform is allocated on the floor of the warehouse, which must be protected by railings from the area of operation of other mechanisms. From the site, access to all mechanisms, running wheels, lubrication points should be provided.

4.2. The mechanisms located in the upper part of the stacker cranes are serviced from stationary platforms installed on the racks. Access to the sites can be made from a gallery running along the end of the warehouse, or from stairs connecting the sites to the floor. In the latter case, the ladders are installed vertically and attached to the metal structures of the racks.

4.3. When servicing mechanisms located at the top of stacker cranes, it is allowed to use ladders. The ladder must be located at a distance of at least 150 mm relative to the racks.

4.4. The frequency of technical inspections is established depending on the production conditions, but at least once a month. During a technical inspection, the motor should be cleaned of dust, the reliability of contact connections, grounding and connection with the drive mechanism should be checked.

4.5. During preventive maintenance, the engine should be disassembled, internally cleaned, and the bearings lubricated. Lubrication is changed after 4000 hours of operation, but at least once a year. Before filling with fresh grease, the bearings are thoroughly flushed.

4.6. In order to reduce the noise that occurs during the operation of the stacker crane, it is necessary to prevent the carts from jamming when moving along the upper guide I-beam. Joints should be cleaned and bearings lubricated.

4.7. In order to reduce the noise that occurs when the stacker crane stops and when moving at low speed, it is necessary to clean the welds and irregularities on the crane track, adjust the side rollers (4 pcs.) on the trolley.

4.8. In the event of a creak and jamming when lifting the forklift, it is necessary to eliminate the malfunction in the bearing supports of the forklift, clean and lubricate the guide columns.

4.9. Turn on and adjust the electrical equipment of the stacker crane after completion of all installation work.

4.10. All work done on the repair and lubrication of the stacker crane units must be recorded in the passport for the crane.

4.11. When carrying out maintenance and repair of the stacker crane, do not leave the tool on the steps and in other places, as injury may occur if the tool falls.

4.12. Tools and accessories should only be used for their intended purpose. During disassembly and assembly work, it is necessary to use special pullers, keys, screwdrivers.

4.13. It is not allowed to unscrew the nuts with a chisel and hammer. Nuts that are difficult to unscrew should be moistened with kerosene, and then unscrewed with a wrench.

4.14. When removing and setting up large components and assemblies of a stacker crane, it is necessary to use lifting and transport devices. The slinging of these units should be carried out in the slinging points marked with a paint different from the general color of the machine with a chain designation.

4.15. When carrying out assembly work, the alignment of the holes should be checked with a beard.

4.16. When working on a grinding machine, it is necessary to use a protective screen or goggles.

4.17. Before starting work using a 127 or 220 V power tool, you must put on dielectric gloves and overshoes. A rubber mat or dry wooden floor should also be used when working.

4.18. Before starting work with a pneumatic tool, it is necessary to press a chisel or hammer to the surface to be treated, and then turn on the air.

5. Safety requirements in emergency situations

5.1. When the cabin safety devices are triggered (due to a loose or broken rope), the operator must:

turn off the emergency stop button of the stacker crane;
call an emergency repair team by giving a sound signal;
turn off the automatic starter;
stay in the cockpit until the arrival of the emergency team.

5.2. In the event of a fire:

stop work;
put the crane in the place intended for parking;
turn off all mechanisms;
turn off the switch on the switchboard;
call the fire brigade, inform management and take measures to extinguish the fire.

5.3. In case of injury, you should immediately stop work, notify the administration, seek medical help and inform the work manager.

In case of accidents with another worker, first aid should be provided to him and measures should be taken to evacuate the injured to a medical facility.

6. Safety requirements at the end of work

6.1. At the end of the work of the stacker crane, the operator must:

lower the lifting platform to the lower position;
put the stacker crane in the place intended for parking;
turn off the automatic starter;
remove the blocking key from the socket of the control panel;
close the doors in the operator's cab and the doors of the fence of the parking lot of the stacker crane to the lock;
turn off the switch on the switchboard;
inform the shift worker or the head of the section about all the malfunctions noticed during work, and make an appropriate entry in the logbook;
take off your work clothes and take a shower.

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