Lockout Tagout (LOTO) Safety Procedures

Lockout Tagout (LOTO) procedures are essential safety practices used to prevent the unexpected startup or release of hazardous energy from machinery and equipment during maintenance or servicing. These procedures ensure that equipment is properly isolated from all energy sources and cannot be inadvertently activated, thus protecting workers from potential harm.

General LOTO Procedure

The following steps outline a general LOTO procedure that should be adapted to the specific equipment and energy sources involved:

1. Preparation: Identify all energy sources (electrical, mechanical, hydraulic, pneumatic, thermal, etc.) and understand how to isolate them. Consult equipment-specific LOTO procedures and energy control plans.
2. Notification: Inform all affected employees that the equipment will be shut down and locked out for maintenance.
3. Shutdown: Shut down the equipment using normal operating procedures. Avoid simply using the emergency stop, as this may not isolate all energy sources.
4. Isolation: Isolate the equipment from all energy sources by disconnecting or deactivating energy-isolating devices such as circuit breakers, valves, and disconnect switches.
5. Lockout/Tagout Application: Apply lockout devices (locks) and tagout devices (tags) to each energy-isolating device. The lockout device should secure the energy-isolating device in the safe or off position. The tagout device should warn against unauthorized reconnection of energy. Each authorized employee performing the maintenance should apply their own lock and tag.
6. Stored Energy Control: Relieve, dissipate, or restrain all stored or residual energy. This may involve grounding electrical circuits, bleeding hydraulic or pneumatic pressure, allowing hot components to cool, or blocking mechanical movement.
7. Verification: Verify that the equipment is effectively isolated by testing the equipment controls (start buttons, switches) to ensure it cannot be started. Also, inspect the isolation points to confirm that energy sources are fully disconnected.
8. Maintenance/Servicing: Perform the necessary maintenance or servicing work.
9. Removal of Lockout/Tagout: After the maintenance or servicing is complete and the equipment is ready for normal operation, remove the lockout and tagout devices. This should be done only by the authorized employee who installed them. Before removing the devices, ensure that all tools and materials have been removed, all employees are safely positioned, and the equipment is operationally ready.
10. Notification of Startup: Before restarting the equipment, notify all affected employees that the lockout/tagout devices have been removed and that the equipment is ready to be restarted.
11. Equipment Startup: Restart the equipment using normal operating procedures.
12. Restarting Procedure: Turn key of Platform/Ground Select switch to Ground. Pull the Power/Emergency Stop switch to On. Push the Engine Start switch until engine starts. Allow engine to warm-up for a few minutes at low speed before applying any load. After engine has had sufficient time to warm up, push in the Power/ Emergency Stop switch and shut engine off. Turn Platform/Ground Select switch to Platform. From Ground Control Console, pull Power/ Emergency Stop switch out.

Specific Considerations for Boom Lifts (Based on Source Documents)

The provided source documents relate to the operation of JLG boom lifts. While they don't explicitly detail LOTO procedures, they offer insights into starting and operating these machines, which can inform LOTO practices.

• Ground Control Station: Initial starting should always be performed from the Ground Control station.
• Engine Starting Cautions: If the engine fails to start promptly, do not crank for an extended time. Should the engine fail to start again, allow the starter to cool off for 2-3 minutes. If the engine fails after several attempts, refer to the engine maintenance manual.
• Diesel Engine Considerations: Diesel engines only: After turning on ignition power, the operator must wait until the glow plug indicator light goes out before cranking the engine.

Detailed Steps for Standstill Cleaning (Example Related Procedure)

The following conditions must be met to perform Standstill Cleaning:

• Machine must be stationary
• Boom in the stowed position
• No personnel in platform
• Engine must be idling
• Coolant temperature must be above 104° F (40° C)
• Diesel Exhaust Fluid (DEF) tank must not be frozen
• Machine in Ground Station mode

Important Considerations

• Training: All authorized employees must receive comprehensive training on LOTO procedures, including the recognition of hazardous energy sources, the methods for energy isolation and control, and the requirements of the LOTO standard.
• Equipment-Specific Procedures: Generic LOTO procedures should be supplemented with equipment-specific procedures that detail the specific steps for isolating and locking out each piece of equipment.
• Periodic Inspections: LOTO procedures should be periodically inspected to ensure that they are effective and that employees are following them correctly.
• Documentation: Maintain detailed records of LOTO procedures, training, inspections, and equipment-specific information.

Disclaimer: This information is for guidance only and does not constitute a complete safety program. Consult applicable regulations and industry standards for specific requirements.

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